Download OVERHAUL MANUAL - Red Sky Ventures

OVERHAUL MANUAL
MODELS L/TSIO-360-RB
Courtesy of Bomar Flying Service
www.bomar.biz
FORM NO. X30596A Supplement 1
© 1998
FAA APPROVED
FEBRUARY 1998
INTENTIONALLY
LEFT
BLANK
ii
About…
CURRENT STATUS OF PAGES AS OF:
FEBRUARY 1998
See “Manual Revisions,” in the introduction section for distribution procedure.
THE ORIGINAL DATE OF THIS PUBLICATION IS FEBRUARY 1998. INSERT LATEST PAGES;
DESTROY SUPERSEDED PAGES.
WARNING
If the user of this manual is uncertain whether all current revisions have been
incorporated into the manual, contact Teledyne Continental Motors. Do not perform
any operation, maintenance, installation or other operation until the manual is
confirmed current.
MODEL: L/TSI0-360-RB
PAGE
ALL
STATUS
ORIGINAL
FORM X30596AS1
PAGE
ALL
STATUS
ORIGINAL
PAGE
ALL
STATUS
ORIGINAL
PAGE
ALL
STATUS
ORIGINAL
iii
Replacement Parts
WARNING
Use only parts meeting the engine type design.
Replacement Parts
Beware of replacement parts, materials and
accessories that may be sold as aircraft quality
but whose origin and quality are not known.
These parts may be deceptively advertised as
"unused," "like new," or "remanufactured," and
purchasers are often unaware that they are not
eligible for use on certificated aircraft. The
hazards involved in installing these types of
parts on your aircraft are obvious.
Know Your Supplier
Many original parts and components are copied
and the copies are sold at discounted prices for
installation on U.S. certified aircraft. An
original manufacturer's part is often used as a
guide to make duplicates that appear to be as
good as the original, but there are many
unknowns about the quality of design, materials,
and workmanship. Other factors that go into
quality parts are the degree of heat treating and
plating, and inspections, tests, and calibrations.
Unfortunately, a cheaply produced part that
looked "as good as the original" is usually found
out too late.
Federal Aviation Regulations FAR 43.13 and
FAR 145.57 specify performance rules for
replacement of parts and materials used in the
maintenance and alteration of United States
certificated aircraft. FAR 91.403, FAR 121.363,
FAR 123.45, and FAR 135.143 (a) holds the
owner/operator responsible for the continued
airworthiness of the aircraft, and that includes
the quality of replacement parts.
Identifying Approved Parts
Approved serviceable replacement parts are
identified by:
1. Federal Aviation Administration (FAA) Form
8130-3 Airworthiness Approval Tag. An
Airworthiness Approval Tag identifies a part or
group of parts that have been approved by an
authorized FAA representative.
iv
2. FAA Technical Standard Order (TSO)
number and identification mark indicating that
the part or appliance was manufactured in
accordance with the requirements of FAR 21
Subpart O.
3. FAA Parts Manufacturer Approval (PMA)
symbol with the manufacturer's name, part
number, make and model of the type certified
product on which the part can legally be
installed stamped on the part. An FAA/PMA is
issued under FAR 21.305. Make and model
information may be on a tag attached to the part.
4. Shipping ticket, invoice, or other document
which verifies that the part was manufactured
by a facility that was holding an FAA Approved
Production Inspection System Certificate issued
under FAR 21 Subpart F, or by a manufacturer
holding an FAA Production Certificate issued
under FAR 21 Subpart G.
5. Certificate of airworthiness for export issued
by governments in countries other than the
United States of America under the provisions
of FAR 21 Subpart N.
It's Your Responsibility
The owner/operator is responsibile for the
continued airworthiness of the aircraft. In
accordance with FAR, certification of materials,
parts and appliances for return to service for use
on aircraft is the responsibility of the
person/agency who signs the approval. To
insure the continued safe operation of your
aircraft, you must exercise great care when
inspecting, testing, and determining the
acceptability of all parts and materials. A very
important part of this is verifying the origin of
all materials, parts, and accessories that are used
on your aircraft.
About…
Notice to all users
This manual does not contain operating,
maintenance, overhaul or installation information for
supplemental type certificated components or
systems. This manual contains information on
engines, components and systems designed, tested
and certified by TCM in accordance with the
pertinent type design data.
The following publication contains overhaul
information. All personnel involved with these
functions must thoroughly read and understand the
information provided; these instructions inform of
the procedures necessary to maintain continued
airworthiness and they must be followed carefully.
This manual contains no warranties, either expressed
or implied.
Publication Format
This publication is formatted for practical use and
ease of reference. Chapter and page numbering are
independent so that revisions can be made without
affecting the entire publication. Due to the large
volume of information necessary for overhaul,
chapters are independently numbered. For example,
chapter 1 begins on page 1; chapter 2 begins again
with page 1, etc. To locate information easily, use
the Publication Table of Contents and the Chapter
Contents provided at each division.
WARNING
This manual, the Service Documents, the
Maintenance Manual and the Parts Catalog
constitute the instructions for Continued
Airworthiness prepared by TCM as
approved by the FAA, pursuant to FAR Part
33. As required by FAR § 43.13, each person
performing
overhaul,
maintenance,
alteration or preventive maintenance on the
engine or accessories must use the methods,
techniques and practices prescribed in the
Instructions for Continued Airworthiness.
Failure to comply with the Instructions for
Continued Airworthiness may result in
engine malfunction, engine failure, injury or
death.
The Mechanic
Prior
to
alteration
performing
or
maintenance,
maintenance the
overhaul,
preventive
mechanic must meet requirements of FAR 65 and
must follow FAR Parts 43, 91 and 145 as applicable.
Use this manual in conjunction with Teledyne
Continental Motors (TCM) service documents,
related publications, accessory manufacturer’s
instructions, FAR and FAA Advisory Circulars.
Notes, Cautions and Warnings…
NOTE...
Special interest information which may
facilitate performance of a procedure or
operation of equipment.
CAUTION...
Used to emphasize certain information or
instructions which if disregarded may result in
damage to engine or accessories.
WARNING
Used to provide warning with respect to
information and/or instructions which if
disregarded will endanger personnel and/or
severely damage the engine resulting in
subsequent engine malfunction or failure.
Notes, cautions and warnings do not impose undue
restrictions. They are inserted to obtain maximum
safety, efficiency and performance. Abuse, misuse
or neglect of equipment can cause eventual engine
continued…
malfunction or failure.
Remember...
Notes, Cautions, and Warnings do not impose
undue restrictions. They are provided to help
you obtain maximum safety, efficiency, and
performance. Any misuse, abuse, or neglect of
the engine or related equipment can eventually
cause engine malfunction or failure.
v
INTENTIONALLY
LEFT
BLANK
vi
Chapter 1
Publication Table of Contents
COVER PAGES
PAGE
Status Page ....................................................................................................................iii
Replacement Parts Warning ..........................................................................................iv
Notice To All Users.......................................................................................................v
Definition of Notes, Cautions and Warnings ................................................................v
Chapter Index
CHAPTER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
PAGE
Introduction.........................................................................................................1-1
Tools, Equipment, Sealants and Lubricants ........................................................2-1
Airworthiness Limitations...................................................................................3-1
Standard Practices ...............................................................................................4-1
Reciprocating Engine Overhaul ..........................................................................5-1
Engine Disassembly............................................................................................6-1
Exhaust System ...................................................................................................7-1
Ignition System ..................................................................................................8-1
Fuel Injection System..........................................................................................9-1
Induction System.................................................................................................10-1
Air Conditioning .................................................................................................11-1
Electrical Charging System.................................................................................12-1
Starting System ...................................................................................................13-1
Accessory Case ...................................................................................................14-1
Lubrication System .............................................................................................15-1
Cylinders And Pistons.........................................................................................16-1
Crankcase............................................................................................................17-1
Engine Drive Train .............................................................................................18-1
Final Assembly ...................................................................................................19-1
Post Overhaul Adjustment And Test ..................................................................20-1
vii
Chapter 1
INTENTIONALLY
LEFT
BLANK
viii
Chapter 1
CHAPTER 1
SECTION
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
PAGE
Introduction.........................................................................................................1-2
Scope...................................................................................................................1-2
Definition of Terms.............................................................................................1-2
Manual Revisions................................................................................................1-3
Related Publications............................................................................................1-3
Service Documents .............................................................................................1-4
Service Reports and Inquiries .............................................................................1-4
Engine Design Features ......................................................................................1-4
1-1
Chapter 1
1-1 INTRODUCTION
This overhaul manual and publications listed in
Section 1-5, "Related Publications," contain the
information necessary to overhaul an aircraft
engine when it reaches manufacturers specified
time between overhaul (TBO).
For a list of chapters contained in this manual
refer to the Chapter Index on page vii.
For a list of sections, figures and tables contained
in each chapter, see the first page of each chapter.
The pages, figures and tables contained in this
publication are numbered consecutively.
This manual covers the L/TSI0-360 RB engine
models.
1-2 SCOPE
This publication contains the information
necessary to disassemble, clean, inspect, repair
and replace, reassemble, adjust and test the above
model engines.
1-3 DEFINITION OF TERMS
In this manual, front, rear, left and right refer to
the engine as viewed from the accessory end. The
accessory end is the rear and the propeller flange
is the front of the engine. Cylinders are numbered
starting from the rear, with odd numbers on the
right and even numbers on the left.
1-4 MANUAL REVISIONS
Teledyne Continental Motors manuals are revised
as necessary. Revisions to this manual will be
furnished to purchasers who fill out and return the
registration post card located in the front of this
manual.
Page iii, "Current Status Of Pages," is updated at
each revision. Remove and discard the old page
iii. Insert the new page iii as a record of which
revisions have been incorporated into the manual.
1-2
WARNING
If for any reason the user of this manual
is uncertain whether all current revisions
have been incorporated into the manual,
contact Teledyne Continental Motors or
a TCM Distributor to confirm the
manual is the most current revision. Do
not use the manual and do not perform
any overhaul procedures or other
operations upon the engine or
accessories until the manual has been
confirmed to be current.
This manual is current and correct to the
best of Teledyne Continental Motors
knowledge at the time of publication.
Teledyne Continental Motors solicits and
encourages users comments regarding
suggested changes to this manual (a post
card is provided at the front of the
manual for this purpose.) Routine
recommended changes or questions
should be sent to:
Teledyne Continental Motors
P.O. Box 90
Mobile, Alabama 36601
ATTN:Technical Publications
Department
If
the
user
observes
incorrect
information or mistakes in this
publication that may affect safety in any
manner, immediately call the Technical
Publications Department of Teledyne
Continental Motors at (334) 438-3411, or
contact a Teledyne Continental Motors
Distributor or the Federal Aviation
Administration.
Chapter 1
1-5
RELATED PUBLICATIONS
The following is a listing of related manuals:
1.
Maintenance and Operators Manual for L/TSI0-360-RB, Form X30645A
2.
Illustrated Parts Catalog for L/TSI0-360-RB, Form X30597A Supplement 1.
3.
Operator Installation Manual for TSI0-360-RB, Form X30644.
4.
Teledyne Continental Motors Aircraft Engine Service Documents (including service bulletins).
5.
Fuel Injection Manual, Form X30593A.
6.
Starter Service Instructions, Form X30592.
7.
TCM Ignition Systems Master Service Manual, Form No. X40000.
8.
Alternator Maintenance and Parts Catalog, Form No. X30531-3.
The above publications can be ordered through your Teledyne Continental Motors Distributor
or ordered directly, if prepaid, from:
Teledyne Continental Motors
P. 0. Box 90
Mobile, Alabama 36601
ATTN: Publication Sales Department
Telephone: (334) 438-3411
For price information on the above publications request TCM Publications Pricing Index of
Current Publications and Optional Publications.
9.
Slick Ignition Systems Master Service Manual Index and Order Form No. F-1 1 00. Order through:
Slick Aircraft Products, Unison Industries
530 Blackhawk Park Avenue
Rockford, Illinois 61104
ATTN: Subscription Department
Telephone: (815) 965-4700
11. American Society for Testing and Materials (ASTM). Order through:
ASTM 1916 Race Street, Philadelphia, PA.
19103-1187 USA
Ph: (215) 299-5400
12. Overhaul Manual for Aircraft System Turbochargers and Overhaul Manual for Aircraft System Valves
and Controllers. Order Through:
Airesearch 232 W. 190 Street
Torrence, California
90504-6094, (213) 323-9500.
13. Fuel System Manuals, Form 15-338, RSA5 Operator and Service Manual and Form 15-900, RSA5AD2
Overhaul Instructions,
Precision Airmotive Corporation
3220 100TH Street S.W. #E
Everett, WA 98204 · USA
(206) 353-8181
1-3
Chapter 1
1-6 SERVICE DOCUMENTS.
Teledyne Continental Motors service documents are
divided into six categories: (1) Mandatory Service
Bulletin, (2) Critical Service Bulletin, (3) Service
Bulletin, (4) Service Information Directive (5)
Service Information Letter and (6) Special Service
Notice (SSN). See Section 1-5, "Related
Publications," for service document ordering
information.
SERVICE DOCUMENT
CATEGORY DEFINITIONS
CATEGORY 1: "MANDATORY SERVICE
BULLETIN" (MSB)- Service documents relating
to known or suspected hazards to safety that have
been incorporated in whole or in part in an
Airworthiness Directive (AD) issued by the FAA or
have been issued, at the direction of FAA, by the
manufacturer in order to require compliance with an
already issued AD (or an equivalent issued by
another country's airworthiness authority).
CATEGORY 2: "CRITICAL SERVICE
BULLETIN" (CSB)- Service documents (not
included in Category 1) that have been determined
by the product manufacturer to constitute a threat to
continued safe operation of an aircraft or to persons
or property on the ground unless some specific
action (inspection, repair, replacement, etc..) is
taken by the product owner or operator. Documents
in this category are candidates for incorporation in
an Airworthiness Directive issued by the FAA (but
may not be.)
CATEGORY 3: "SERVICE BULLETIN" (SB)Service documents (not included in Categories 1
and 2) considered by the product manufacturer to
constitute a substantial improvement to the inherent
safety of an aircraft or component of an aircraft.
This "Service Bulletin" category also includes
updates of instructions for continued airworthiness.
CATEGORY 4: "SERVICE INFORMATION
DIRECTIVE" (SID)- Service documents (not
included in Categories 1, 2 or 3) that have been
determined by the manufacturer to be of value to an
owner/operator in the use of a product by enhancing
safety, maintenance or economy.
1-4
CATEGORY 5: "SERVICE INFORMATION
LETTER" (SIL)- This category includes all
information (not included in Categories 1 through 4)
that may be of use to the owner/operator or
maintainer of the aircraft.
CATEGORY 6 “SPECIAL SERVICE
NOTICE” (SSN)-TCM may issue a Special
Service Notice when a product condition can be
rectified by direct contact with each customer to
whom the product was delivered. Special service
notices will be upgraded to Service Bulletins if
confirmation of compliance with the Special
Service Notice cannot be verified by TCM.
1-7 SERVICE REPORTS AND
INQUIRIES.
If for any reason you have an inquiry or require
technical assistance, contact your local TCM
distributor or TCM field representative. Requests
for copies of Teledyne Continental Aircraft
Engine service publications should be made
through your distributor or Teledyne Continental
Motors, P. 0. Box 90, Mobile, AL 36601, ATTN:
Publications Sales Department.
1-8 ENGINE DESIGN
FEATURES
For a complete description of the engine, systems,
components and maintenance of the engine prior to
engine overhaul see the L/TSI0-360-RB Maintenance
Manual, Form X30645A.
Chapter 1
1-9
GLOSSARY
BURNING: As applied to valve heads this term
indicates roughening or erosion due to high
temperature gases escaping past valve faces. In other
instances, it indicates drawing of the temper of steel
parts to a soft (blue) condition, as a result of
overheating, during an absence of lubrication on
moving surfaces, such as, gear teeth subject to high
loading.
NICK: A sharp sided gouge or depression with a "V"
shaped bottom which is generally the result of
careless handling of tools and parts.
BURR: A sharp or rough projection of metal.
RUNOUT: Eccentricity or wobble of a rotating part.
Eccentricity of two bored holes or two shaft
diameters. A hole or bushing out of square with a flat
surface. Usually measured with a dial indicator, and
limits stated indicate full deflection of indicator needle
in one revolution of part or indicator support.
CHAFING: Rubbing action between adjacent or
contacting parts under light pressure which results in
wear.
COLD FLOW: Term used to describe deep and
permanent impressions or cracks caused by hose
clamp pressure.
CRACK: A partial separation of material usually
caused by vibration, overloading, internal stresses,
improper assembly or fatigue.
DENT: A rounded hollow in the surface.
PEENING: A series of blunt depressions in a surface
PITTING: The formation of pockets of corrosion
products on the surface of a metal.
SCORING: Deep grooves in a surface caused by
abrasion. Scoring is caused by fine hard particles that
are forced between moving surfaces, as in a bearing
and journal, or by galling when a moving part is not
supplied with lubricant.
SPALLING: Distress to a loaded surface in which
chips of the hardened surface are broken out.
ELONGATE: To stretch out or lengthen.
EROSION: Carrying away of material by the flow of
hot gases, grit or chemicals.
FRETTING: A condition of surface erosion caused by
a slight movement between two parts that are fastened
together.
GALLING: A severe condition of chafing or fretting
in which a transfer of metal from one part to another
occurs. It is usually caused by a slight movement of
mated parts having limited relative motion and under
high loads.
GROOVED SURFACE: Shallow channels, wider
than scratches and usually smooth resulting from wear
effected by concentrated contact stress.
1-5
Chapter 1
INTENTIONALLY
LEFT
BLANK
1-6
TOOLS
CHAPTER 2
TOOLS, EQUIPMENT, SEALANTS AND LUBRICANTS
Section
2-1
2-2
2-3
2-4
Page
General Information ........................................................................................... 2-2
Possible Special Tool Procurement Sources ...................................................... 2-3
Special Tools...................................................................................................... 2-4
Sealants and Lubricants...................................................................................... 2-8
2-1
TOOLS
2-1
GENERAL INFORMATION
The mechanic should be equipped with a complete set of the necessary tools that include the following:
1.
Wrenches - 1/4” through 1 1/4"
2.
Common and Philips Head Screwdrivers
3.
Pliers - Common, Diagonal Cutters, Needle Nose, Duck Bill, Snap Ring, Safety Wire
4.
Ratchets 1/4", 3/8", 1/2" Drive
5.
Sockets - 1/4”' Drive 5/32" through 1/2",- 3/8" Drive 3/8" through 1" - 1/2" Drive 7/16" through
1-1/ 4"
6.
Sockets (Deepwell) -1/2" Drive, 7/16" through 1"
7.
Feeler Gauges
8.
Leather or Soft Plastic Mallet
9.
Torque Wrenches* 0-500 In. Lbs. and 0-100 Ft. Lbs.
10. Micrometers*
11. Slide Hammer
12. Pullers
13. Thickness Gauges
14. Vernier Calipers*
15. Small Hole Gauges
* Must be currently calibrated, and the calibration must be traceable to the National Bureau of Standards.
2-2
TOOLS
2-2
POSSIBLE SPECIAL TOOL PROCUREMENT SOURCES
—NOTICE—
All tools in the "Special Tool" list are for reference only, and not for the purpose of promoting or suggesting
tools to be purchased from the indicated sources. The following information is given as an aid for special tool
procurement purposes.
COMPANY
ALCOR
Box 32516 10130 Jones Maltsberger Rd.
San Antonio, TX 78284 Ph.512/349-3771
KENT- MOORE
29784 Little Mack
Roseville, Ml 48066-2298 Ph. 800/253-0138
CHAMPION SPARK PLUG, CO.
Box 910, 900 Upton Ave.
Toledo, OH 43661 Ph. 419/535-2461
EASTERN ELECTRONICS, INC.
180 Roberts St.
East Hartford, CT 06108 Ph. 203/528-9821
FEDERAL TOOL SUPPLY CO., INC.
1144 Eddy St.
Providence, Rhode Island 02940 Ph. 800/343-2050
AIRCRAFT TOOL SUPPLY
P.O. Box 4525, 2840 Breard St.
Monroe, LA 71201 Ph. 507/451 -5310
McMASTER-CARR SUPPLY CO.
P.O. Box 4355
Chicago, Illinois 60680 Ph. 312/833-0300
SNAP ON TOOLS
2611 Commerce Blvd.
Birmingham, Alabama 35210 Ph. 205/956-1722
KELL-STROM TOOL COMPANY, INC.
214 Church St.
Wethersfield, CT 06109
FAX CORPORATION
210 South King St.
Danbury, Connecticut 06813 Ph. 203/748-6117
MERRIT PRODUCTS
201 W. Mansville
Compton, California 90224 Ph. 310/639-4242
AERO TEST, INC.©
29300 Goddard Road
Romulus, Michigan 48174 Ph. 313/9465547
PARKER RESEARCH CORPORATION
P.O. Box 1406 Dunedin Fla.
34697 Ph. 1-800-525-3935 Fax. 813-797-3941
GENERAL PRODUCT SUMMARY
Instruments for Light Powered Aircraft
Special Tools
Precision Instruments
Measuring Instruments
Precision Tools, Special Tools
Spark Plugs, lgnitors, Oil Filters
Special Tools
Fuel Pressure Test Equipment
Measuring Instruments
Precision Tools
Piston Position Indicators
Precision Inspection Instruments
Special Tools
Precision Tools
Special Tools
Precision Tools
Special Tools
Precision Tools
Special Tools
Ignition Test Equipment
Ultrasonic Test Equipment
Special Tools
Model 20 ATM-C Porta-Test Unit
Model DA-200 Contour Probe
2-3
TOOLS
2-3
SPECIAL TOOLS
Specific tools listed or equivalent tools marketed by other manufacturers are necessary for overhaul and
maintenance of the aircraft engine.
ITEM
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
NOTE
2-4
TOOL
GENERAL ENGINE RECIPROCATING
646953 Master Orifice Tool for cylinder compression test available from Kent - Moore.
7251 Differential Pressure Cylinder Checker available from Kent - Moore.
IGNITION SYSTEM
Borrough's 3608A Protractor/Timing Indicator Disc or equivalent for setting engine
timing.
Model E25 Timing Indicator available from Eastern Electronics, Inc.
11-9110-1 Magneto Timing Light available from KELL-STROM Tool Company Inc.
FUEL INJECTION
Borrough's 8165 Injector Nozzle Remover and Installer or equivalent.
CHARGING SYSTEM
Borrough's 7726 Tork Band Tension Adjuster or equivalent for Gen./Alt. Belt
Tensioning.
BT-33-73F Belt Tension Gauge available from Kent - Moore.
Borrough's 4973 Generator Drive Holders or equivalent.
Borrough's 61-5 Pulley Puller or equivalent for gen./alt. sheave removal
Borrough's 8091 GEN./ALT. Output Tester or equivalent.
647 Alternator Analyzer Voltage Regulator Tester available from Eastern Electronics,
Inc.
E100 Alternator/Regulator/Battery Tester available from Eastern Electronics, Inc.
Model 29 Voltage & Circuit Tester available from Eastern Electronics, Inc.
STARTING SYSTEM
Borrough's 8093C Bearing Puller or equivalent for needle bearing removal.
Borroughs 23-1 Needle Bearing Installer or equivalent.
LUBRICATION SYSTEM
8048 Oil Pressure Relief Spot Facer available from Kent - Moore.
CYLINDERS
68-3 Push Rod Spring Compressor available from Kent - Moore.
3882 Cylinder Base Nut Wrenches available from Kent - Moore.
Borrough's 8079 Cylinder Base Nut Wrenches or equivalent.
3882, 3882-2 Cylinder Base Nut Wrenches available from Kent - Moore.
3601 Ring Compressor for cylinder installation available from Kent - Moore.
8121 Piston Pin Removers available from Kent - Moore. 24.
3602 Valve Spring Compressor available from Kent - Moore.
545-116 Dial Bore Gauges available from Federal Tool Supply Co., Inc.
CFL10 Cylinder Hone available from Snap On Tools.
No. 1675 Valve Seat Grinder Set "Sioux Brand" available from Aircraft Tool Supply.
AEX 375 Valve Seat Grinder Pilot .437 Dia. available from Aircraft Tool Supply.
K498 Intake Valve Seat Grinding Stone (Roughening 30°) available from Aircraft Tool
Supply.
K428 Intake Valve Seat Grinding Stone (Finishing 30°) available from Aircraft Tool
Supply.
K491 Exhaust Valve Seat Grinding Stone (Roughening 30°) available from Aircraft Tool
Supply.
K21 Exhaust Valve Seat Grinding Stone (Finishing 30°) available from Aircraft Tool
Supply.
Borrough's 5221 Holding Fixture Adapters or equivalent.
See possible sources on page 2-3 for tool procurement
SEE
SECTION
5-4
5-4
12-6
12-7
12-7
13-3
16-5
16-5
16-5
16-5
16-5
16-5
16-5
16-5
17-5
17-5
19-3
20-6
20-6
TOOLS
ITEM
NO
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
TOOL
Borrough's 5221 15A Cylinder Holding Fixture or equivalent.
Borrough's 8156 Cylinder Heating Stand or equivalent.
Borrough's 8086 Valve Seat Insert Remover & Replacer or equivalent.
Borrough's 4910 Installer Valve Seat Insert or equivalent.
Borrough's 4956 Installer Valve Seat Insert or equivalent.
Borrough's 8116 Common Parts Kit or equivalent.
Borrough's 8116-1 B through 15B Boring Bars or equivalent.
Borrough's 8116-1 R through 15R Reamers or equivalent.
Borrough's 8116-1 through 16 Expanding Guide Bodies or equivalent.
4909 Valve Seat (Straight Side) Insert Cutters available from Kent - Moore.
4954 Valve Seat (Straight Side) Insert Cutters available from Kent - Moore.
4985 Valve Seat (Straight Side) Insert Cutters available from Kent - Moore.
5224 Valve Seat (Straight Side) Insert Cutters available from Kent - Moore.
5225 Valve Seat (Straight Side) Insert Cutters available from Kent - Moore.
8135 Valve Seat (Step Side) Insert Cutters available from Kent - Moore.
8136 Valve Seat (Step Side) Insert Cutters available from Kent - Moore.
8138 Valve Seat (Step Side) Insert Cutters available from Kent - Moore.
Borrough's 8122A Common Drive Handle or equivalent.
122 Valve Guide Cleaner available from Kent - Moore.
4981 Valve Guide Remover available from Kent - Moore.
3619 Valve Guide Replacer available from Kent - Moore.
Borrough's 3170 Floating Holder or equivalent.
4981 Valve Guide Remover available from Kent - Moore.
Borrough's 8116-24 through 29 Valve Stem Hole Reamers or equivalent.
3606-CP Reamer (Carbide Tipped) available from Kent - Moore.
3606-HP Reamer (High Speed Steel) available from Kent - Moore.
2848-1 Plug Gauge for valve guide inspection available from Kent - Moore.
4943-1 HS through 5HS Reamers, Valve Guide Boss available from Kent - Moore.
Borrough's 4918 Spark Plug Insert Replacer or equivalent.
Borrough's 4919 Spark Plug Insert Remover or equivalent.
Borrough's 445, 18mm Spark Plug Tap or equivalent for straightening out damaged
2769A13 Rosan® Stud Remover available from McMASTER-CARR Supply Co.
Rosan® is a registered trademark of Fairchild Aerospace Fastener Division. .
8074 Rosan® Lock Ring Installer available from Kent - Moore.
8118 Rocker Arm Bushing Remover/lnstaller available from Kent - Moore.
3610 Reamer Rocker Arm Bushing available from Kent- Moore.
CRANKCASE
Borrough's 8114 Crankcase Through Bolt Removers or equivalent.
L423 Crankcase Splitter available from Kent - Moore.
Borrough's 505 Stud Drivers or equivalent.
ENGINE DRIVE TRAIN
Borrough's 8117A Runout Block Set or equivalent for crankshaft inspection.
Wheel Fax Jr. Mark IV Model O for Crankshaft Ultrasonic Testing available from Fax
Corporation. Operator must be certified by TCM standards.
Borrough's 8087A Polishing Tools for Crankshaft Bearings or equivalent.
3604, 8068 Crankshaft Blade and Damper Bushing Remover/Replacer available from
Kent- Moore..
Borrough's 8077A Bushing Remover & Replacer, Counterweight or equivalent. .
Borrough's 8111A Connecting Rod Fixture or equivalent.
SEE
SECTION
20-6
20-6
21-5
21-5
21-5
22-5
22-5
NOTE... See possible sources on page 2-3 for tool procurement.
2-5
TOOLS
ITEM
NO.
72
73.
74.
75.
76.
77.
78.
79.
80.
TOOL
Borrough's 8072C Adapter Kit or equivalent for connecting rod inspection
8071 Reamers for connecting rod bushing available from Kent - Moore
D-4000 Federal Dimension Air Gauge for connecting rod bushing inspection available
from Federal Tool Supply Co., Inc.
1.00025 Setting Ring for checking 1.0000 to 1.0005 tolerance available from Federal
Tool Supply Co., Inc.
1.00025 Air Plug for checking 1.0000 to 1.0005 tolerance available from Federal Tool
Supply Co., Inc.
5209 Propeller Shaft Oil Seal Installer available from Kent - Moore
OPERATIONAL INSPECTION
85328 Alcor Portable Digital EGT Unit available from Alcor, Inc.
85329 Alcor Portable Digital CHT available from Alcor, Inc.
Model 20 ATM-C Porta-Test Unit available from Aero Test, Inc.©
NOTE...
See possible sources on page 2-3 for tool procurement.
NOTE...
The rights to manufacture Borrough's Tools has been acquired by Kent - Moore.
2-6
SEE
SECTION
22-5
22-5
23-1
23-1
23-2
Sealants And Lubricants
2-4
SEALANTS AND LUBRICANTS
Aviation Engine Oil Ashless Dispersant
Recommended Grade:
Above 40'F ambient air, sea level
SAE 50 or Multi Viscosity
Below 40'F ambient air, sea level
SAE 30 or Multi Viscosity
Manufacturer
Brand Name
BP Oil Corporation
Castrol
Castrol Limited (Australia)
Chevron U.S.A., Inc.
Continental Oil
Delta Petroleum Company
Exxon Company, U.S.A.
Gulf Oil Company
Mobil Oil Company
NYCO S.A.
Pennzoil Company
Phillips Petroleum Company
Phillips Petroleum Company
BP Aero Oil
Castrol Aero AD Oil
Castrol Aero AD Oil
Chevron Aero Oil
Conco Aero S
Delta Avoil Oil
Exxon Aviation Oil EE
Gulfpride Aviation AD
Mobil Aero Oil
TURBONYCOIL 3570
Pennzoil Aircraft Engine Oil
Phillips 66 Aviation Oil, Type A
X/C Aviation Multiviscosity Oil
SAE 2OW50, SAE 2OW60
Quaker State AD Aviation Engine Oil
Red Ram X/C Aviation Oil 2OW50
Aeroshell (R) W
Aeroshell Oil W, Aeroshell Oil W 15W50
Anti-Wear Formulation Aeroshell Oil W 15W50
Aeroshell Oil W, Aeroshell Oil W 15W50
Anti-Wear Formulation Aeroshell Oil W 15W15
Sinclair Avoil
Texaco Aircraft Engine Oil - Premium AD
Total Aero DM 15W50
Union Aircraft Engine Oil HD
Quaker State Oil & Refining Company
Red Ram Limited (Canada)
Shell Australia
Shell Canada Limited
Shell Oil Company
Sinclair Oil Company
Texaco Inc.
Total France
Union Oil Company of California
Break-in Oil
MIL-C-6529 Type 11 Corrosion preventive mineral oil.
NOTE... Mineral oil conforming with MIL-C-6529 Type 11 contains a corrosion preventive additive and must not
be used for more than 25 hours or six months, whichever occurs first. If oil consumption has not stabilized in this
time, drain and replenish the oil and replace the oil filter.
.
2-7
Sealants And Lubricants
Preservative Oil
TYPE
SUGGESTED SOURCES
APPLICATION
MIL-C-6529 Type 11
(Aeroshell Fluid 2F or equivalent)
For Temporary storage (up to 90
days)
MIL-P-46002, Grade 1 oil
(NOX RUST VCI-105 or
equivalent) May be purchased
through: Rock Island Lubricant &
Chemical Co. P.O. Box 5015 1320
1st Street Rock Island, Illinois
61204 Phone: 1 -800-522-1150
For Indefinite storage
Lubricants
TYPE
SUGGESTED SOURCES
APPLICATION
Molyshield Grease
May be purchased
through: American Lubricants
1227 Deeds
Dayton, Ohio 45401
Phone: (513) 222 - 2851
Needle bearings and ball bearings
Valve stems
All ACC. drive splines and couplings
Idler gear and pin
Fuel injection controls, o-rings,
springs, shafts and bushings
Magneto rubber drive bushings
Oil pump and scavenge pump gear
shafts, ends and teeth. Oil pump and
scavenge pump housing and cover gear
contact areas.
Starter worm gear drive teeth and bevel
gear teeth
Dow Corning® G-N Paste [Dow
Corning G-N Paste is a registered
trademark of Dow Corning
Corporation.]
For Distributor information call
1-800-248-2481, have state & city
information available
Camshaft lobes and lifter faces
Alvania (Shell #2)
For Distributor information
Shell Product Information Center,
Phone: 1-800-231-6950
Front crankshaft oil seal
Apply light coat at point of contact
between nut seat and ferrule on
ignition lead
MIL-S-3545C Grease (Shell #5)
Shell Product Information Center,
Phone: 1-800-231-6950
Fuel injection linkage pivot points,
throttle shaft bushings, lever bushings
Permatex Maintain® Lubricant
For Distributor information call:
Permatex Customer Service @
Phone: 1-800-641-7376
Fuel injection linkage pivot points,
throttle shaft bushings, lever bushings
2-8
Sealants And Lubricants
Lubricants
TYPE
SUGGESTED SOURCES
APPLICATION
646943 - Anti Seize Lubricant
or
May be purchased through your
local TCM Distributor or For
Distributor information: Loctite
Customer Service @
Phone: 1-800-243-4874
All fuel injector nozzles (at cylinder
head)
Loctite Anti-Seize Lubricant 767
Oil temp. control valve (Vernatherm)
Exhaust studs (nut end before
Courtesy of Bomar Flying Service torquing)
www.bomar.biz
All .3125 and larger studs unless
otherwise specified
All mechanical tach drive housing
threads not through to an oil source
Air reference fittings on all throtle
bodies
Lubricants
TYPE
SUGGESTED SOURCES
APPLICATION
See Aviation Engine Oil Ashless
Dispersant Table
Cylinder stud threads and through bolt
threads, crankcase stud threads,
connecting rod bolt and nut threads
and engine accessory stud threads
where specified torques are utilized
Approved Clean Break-In Oil
See Break-In Oil Table
Crankshaft bearings, connecting rod
bearings, camshaft bearings,
tachometer gears and adapters,
accessory spur gear teeth, starter cone,
bushing and nut, starter adapter clutch
spring (ID & OD), sealing surface of
valve guide seals, pistons, piston pins
and piston rings, rocker arms, pivots,
valves and tappets, thrust washers and
o-rings, oil filter adapter seals
CHAMPION® - Spark Plug
Thread Lubricant No. 2612
[CHAMPION® is a registered
trademark of Cooper Industries.]
For Champion Products Distributor
information:
Phone: 803-843-5400
Spark plugs
WD-40 orChesterton No. 4
Chesterton Technical Product
Information
Phone: (508) 469-6783
Induction system hose connections
Dow Corning® No. 4
For Distributor information call
1-800-248-2481, have state & city
information available
Spin-on oil filter rubber seals
Gasket, governor pad (both sides)
Approved, Clean, 50 Weight
Ashless Dispersant Oil
2-9
Sealants And Lubricants
Sealants
TYPE
SUGGESTED SOURCES
APPLICATION
LUBRIPLATE® 930 AA
(P/N L0096-035)
For Distributor information Call
LUBRIPLATE®
@ Phone: 1-800-733-4755
Apply to the outside diameter of valve
guides at installation
TCM P/N 654514 CRC 336 Rust
Preventative Compound
May be purchased through
your local TCM Distributor
Spray exhaust end of turbocharger for
engine preservation
Permatex Aviation Grade 3D
For Distributor information call:
Permatex Customer Service @
Phone: 1-800-641-7376
Crankcase parting face, oil pump
covers, scavenge pump covers
and
#641543 Silk Thread
and
May be purchased through
your local TCM Distributor
#646942 Gasket Maker
or
May be purchased through
your local TCM Distributor
Loctite Gasket Eliminator
515 Sealant
For Distributor information call:
Loctite Customer Service @
Phone: 1-800-243-4874
653692 - Primer
May be purchased through
your local TCM Distributor
Crankcase crankshaft nose oil seal
area
or
Loctite LocQuic Primer 7649
For Distributor information:
Loctite Customer Service @
Phone: 1-800-243-4874
#646942- Gasket Maker
May be purchased through your
local TCM Distributor
or
Loctite Gasket Eliminator
515 Sealant
For Distributor information:
Loctite Customer Service @
Phone: 1-800-243-4874
Engine nose seal, outside diameter of
all uncoated oil seals except fuel pump
adapter seal, 642910 oil seal outside
diameter, between oil sump and oil
sump gaskets
Sealants
TYPE
SUGGESTED SOURCES
APPLICATION
#642188 - Gasket Sealant
(TCM) 1.5 oz. tube
May be purchased through your
local TCM Distributor or
K & W Copper Coat
For Distributor information r-all:
K & W Products Customer
Phone: 1-800423-9446
Accessory case to crankcase gasket
crankcase side only, oil cooler gasket
both sides, pressed in plugs, parting
line areas at three way joints sump to
crankcase to accessory case,
Loctite Teflon PS/T Pipe Sealant
For Distributor information:
Loctite Customer Service @
Phone: 1-800-243-4874
Pipe threads (except fuel system
fittings), pressure relief valve housing
threads, tach drive threads, stud holes
that are exposed to oil
2-10
Sealants And Lubricants
Sealants
TYPE
SUGGESTED SOURCES
APPLICATION
#646940 - F/I Sealant
May be purchased through
your local TCM Distributor
All pipe thread fittings in fuel
injection system (use sparingly on
male threads only)
or
Loctite Hydraulic Sealant 569
For Distributor information:
Loctite Customer Service,
Phone: 1-800-243-4874
Miller Stephenson
MS 122/CO2 Spray
For Distributor information:
Miller-Stephenson Customer
Service,
Phone: 1-800-992-2424
Ignition harness terminals at magneto
block end
Adhesives
TYPE
SUGGESTED SOURCES
APPLICATION
646941 High Strength Adhesive
Sealant or Loctite 271
May be purchased through your
local TCM Distributor
Cylinder deck studs, squirt nozzles,
fuel manifold valve diaphragm and
plunger assembly, crankshaft nose seal
retainer bolts
653696 Primer or Loctite
LocQuic Primer 7471
For Distributor information:
Loctite Customer Service,
Phone: 1-800-243-4874
649306 Sealant (optional 646940)
or Loctite Adhesive Sealant 222
(optional Loctite Hydraulic Sealant
569)
May be purchased through
your local TCM
3M Brand EC1252 White Spot
Putty
Through stud holes on accessory end of
crankcase, manifold valve to bracket
screws
For Distributor information:
Loctite Customer Service,
Phone: 1-800-243-4874
3M
Cylinder deck stud nuts, through bolt
nuts, magneto flanges, throttle body
and fuel metering unit
2-11
Sealants And Lubricants
Miscellaneous
TYPE
SUGGESTED SOURCES
APPLICATION
TCM P/N 626531-1
Enamel - Gold (1 qt)
TCM P/N 626531-2
Enamel - Gold (1 gal)
May be purchased through
your local TCM Distributor
High temp. paint for cosmetic and
corrosion protection
TCM P/N 535001S
Lockwire -.032 inch dia. Steel,
Corrosion Resistant
May be purchased through
your local TCM Distributor
Where applicable for lockwiring
"ACCELAGOLD"
Turco® Products
Tucker, GA 30084
[Accelagold is manufactured by
Turco® Products, Inc.]
For sales and service: Elf Atochem
N.A. Turco® Products Div. P.O.
Box
195 State Route 95 West Marion,
Ohio, 43302,
Corrosion protection interior and
ENGINE PRESERVATION KIT
• dehydrator plugs
• desiccant bags
• streamers, warning sign
• preservative oils
2-12
215-419-5376
May be purchased through:
TANAIR
P.O. BOX 117
Glenwood, MN 56334
(US & CAN) 1-800-4432136
(MN) 1-800-862-2443
exterior aluminum parts
Engine Preservation
Chapter 3
AIRWORTHINESS
LIMITATIONS
This Airworthiness Limitations section has been
FAA approved and specifies maintenance
required under §§ 43.16 and 91.403 of the
Federal Aviation Regulations unless an
alternative program has been FAA approved.
Federal Aviation Regulations §§ 43.16 and
91.403 require owner/operator compliance with
all maintenance limitations in this section
concerning mandatory replacement times,
inspection intervals and other related procedures
that are specific to this engine. Any such
limitations listed below are part of the design
limits of the engine and the engine was type
certificated based upon required owner/operator
compliance with the limitations.
1.
Mandatory Replacement Times.
Subject to additional information contained
in FAA Airworthiness Directives (AD)
issued after the date of certification, the
engines covered in this manual do not
contain any components having mandatory
replacement times required by type
certification.
2.
Mandatory Inspection Intervals.
Subject to additional information contained
in FAA Airworthiness Directives (AD)
issued after the date of certification, the
engine does not require specific intervals of
inspection pursuant to type certification.
3.
Other Related Procedures
Subject to additional information contained
in the Airworthiness Directives (AD)
issued after the date of certification, there
are no other related procedures required
pursuant to the type certification for this
engine.
4.
Distribution of Changes to Airworthiness
Limitations.
Changes to the Airworthiness Limitations
section constitute changes to the type
design of this engine and require FAA
approval. Such changes will be published
in FAA Airworthiness Directives (AD).
NOTE
The limitations in this section apply only to
specific limitations which are part of the engine
design. Under the Federal Aviation Regulations
numerous other additional limitations are
applicable to this engine and it's accessories. For
example Federal Aviation Regulation Parts 91
and 43, among other parts, define inspection
criteria,
maintenance
requirements
and
procedures that are applicable to this engine. It
is the responsibility of the owner / operator to
maintain the engine in an airworthy condition
by complying with all applicable Federal
Aviation Regulations and by performing
maintenance in accordance with TCM
Instructions for Continued Airworthiness, which
consist of TCM publications and service
documents.
3-1
Chapter 3
INTENTIONALLY
LEFT
BLANK
3-2
Chapter 4
CHAPTER 4
STANDARD PRACTICES
SECTION
4-1
4-2
4-3
4-4
4-5
4-6
4-7
PAGE
General ..................................................................................4-2
Lockwire Procedure..............................................................4-3
Tab Washer Procedure..........................................................4-5
Cotter Pin Procedure.............................................................4-5
Connecting Rod Cotter Pin Procedure .................................4-6
Application Of Adhesives.....................................................4-7
Installation Of Gaskets..........................................................4-7
FIGURE
4-1
4-2
4-3
4-4
4-5
PAGE
General Lockwire Procedure ................................................4-3
General Lockwire Patterns ...................................................4-4
General Tab Washer Installation Procedure.........................4-5
General Cotter Pin Installation .............................................4-6
Connecting Rod Cotter Pin Installation................................4-6
4-1
Chapter 4
4-1 GENERAL
To facilitate and insure proper reinstallation, tag or
mark all parts and hardware as they are removed or
disassembled.
Tag any unserviceable parts or units for investigation
and possible repair. Take extreme care to prevent
lockwire, nuts, washers, dirt, etc., from entering the
engine on or off the aircraft. Make use of protective
caps, plugs and covers to insure openings are
unexposed.
CAUTION…
Dust caps used to protect open lines must be installed
OVER the tube ends and NOT IN the tube ends. Flow
through the lines will be blocked if lines are
inadvertently installed with the dust caps in the tube
ends.
If anything is dropped into the engine work must be
stopped immediately and the item removed.
Insure all parts are thoroughly clean and lubricated as
specified before assembling.
4-2
All lockwire and cotter pins must fit snugly in holes
drilled in specific hardware. On castellated nuts,
unless otherwise specified, the cotter pin head must fit
into a recess of the nut with the other end bent such
that one leg is back over the stud and the other is
down flat against the nut in accordance with Section
4-4. Use only manufacturer specified corrosion
resistant steel cotter pins. All lockwire utilized on
TCM engines must conform to MS20995 Condition
A.
When replacing gaskets, packings, or rubber parts use
the type or composition specified by the
manufacturer.
Make sure replacement nonmetallic and metallic parts
show no sign of storage deterioration. Parts exceeding
specified shelf life limitations must not be used.
When a hammer is required to come in direct contact
with an engine part during assembly or disassembly,
use a mallet made of plastic or rawhide material only.
Parts removed from the engine must be cleaned and
inspected in accordance with the specified instructions
located in the applicable system chapter.
Chapter 4
4-2 LOCKWIRE PROCEDURE
Lock wiring is the securing together of two or more
parts with lockwire installed in such a manner that any
tendency for a part to loosen will be counteracted by
additional tightening of the lockwire.
All lockwire utilized on TCM engines must conform
to MS20995 Condition A. Most bolts utilized in TCM
engines that require lockwiring will use .032 lockwire
and require twisting at a rate of 7 to 10 twists per inch.
Smaller lockwire (when specified or required) will
require twisting at a rate of 9 to 12 twists per inch.
Lockwire must be new at each application.
Lockwire must be pulled taut while being twisted and
caution must be exercised during the twisting
operation to keep the lockwire tight without
overstressing. See Figure 4-1, "General Lockwire
Procedure," for steps in applying lockwire.
FIGURE 4-1. GENERAL LOCKWIRE PROCEDURE
4-3
Chapter 4
Various examples of lockwiring are shown in Figure
4-2, "General Lockwire Patterns."
1. Check the units to be lockwired to insure
they have been correctly torqued. Applying
torque that is above or below specified limits
to obtain alignment of the holes is not
permitted.
2. It is desirable to have the holes parallel, but
this is not a necessity. For right hand threads,
the lockwire shall be installed in such a
manner that the strand through the hole will
have a tendency to pull the unit clockwise.
3. Insert half of the required lengh of lockwire
through the first unit and bend around the
head of the unit. The direction of wraps and
twist of strands shall be such that the loop
around the unit comes under the strand
protruding from the hole so that the loop will
stay down and will not tend to slip up and
leave a slack loop.
1. Twist the strands while taut until the twisted
part is just short of a hole in the next unit. The
twisted portion should be within one-eighth
(1/8) inch from the hole in either unit.
2. Insert the uppermost strand through the hole
in the second unit and follow the rules in
Paragraph three.
3. After lockwiring the last unit continue
twisting the lockwire to form a pigtail,
providing sufficient twists (four minimum) to
assure that the pigtail will not unravel. Cut off
the excess lockwire and bend the pigtail
toward the part and against the bolt head flats.
DO NOT ALLOW THE PIGTAIL TO
EXTEND ABOVE THE BOLT HEAD.
FIGURE 4-2. GENERAL LOCKWIRE PATTERNS
4-4
Chapter 4
FIGURE 4-3 GENERAL TAB WASHER INSTALLATION PROCEDURE
4-3 TAB WASHER
PROCEDURES
Tab washers are installed by fitting a tab in a tab slot
and bending the remaining tabs firmly against the bolt
or nut flat. Tab washers are used in various locations
in TCM engines and must not be re-used after
removal.
Tabs that are provided to be bent up against the head
flats must be seated firmly with no scarring of the
tabs. This provides proper locking of the unit and
prevents tabs from breaking off.
1. Make certain the holding tab is located in the
tab hole or slot.
2. Check the units to be secured and verify they
have been correctly torqued in accordance
with the specified instructions of the
applicable system section.
3. Bend tabs against the head flats firmly by
tapping them into place with a soft drift. See
Figure 4-3, "General Tab Washer Installation
Procedure."
4-4 COTTER PIN PROCEDURE
Cotter pins are installed by inserting the cotter pin
through a hole in one part, slots in the other part and
spreading the exposed ends.
Cotter pins are not reusable and must be replaced with
a new cotter pin after removal.
1. Torque the nut to the lower limit of the torque
specification. If the slots in the nut do not line
up with one of the holes in the bolt continue
torquing until one does. Do not exceed the
upper limit of the torque specification.
Change the nut if necessary.
2. Insert the cotter pin with the head seated
firmly in the slot of the nut. Bend the ends
over the flat on the nut and the end of the
bolt. Trim the prong lengths as necessary.
3. Seat the prongs firmly against the bolt and
nut. See Figure 4-4, "General Cotter Pin
Installation."
CAUTION…
Do not use side-cutting type pliers to bend the ends
over since the resulting nick could weaken the pin and
allow a portion to become detached.
4-5
Chapter 4
FIGURE 4-4. GENERAL COTTER PIN INSTALLATION
4-5 CONNECTING ROD
COTTER PIN INSTALLATION
When installing cotter pin in connecting rod nuts and
bolts, use the steps in Section 4-4, "Cotter Pin
Procedure," and the following:
1. Use a hammer and soft drift to tap the head of the
cotter pin firmly into the nut slot and bolt hole,
deforming the head until it is flush with or no more
than .030 of an inch above both the flat on the nut and
the end of the bolt. See Figure 4-5, "Connecting Rod
Cotter Pin Installation."
FIGURE 4-5. CONNECTING ROD COTTER PIN INSTALLATION
4-6
Chapter 4
4-6 APPLICATION OF
ADHESIVES
Adhesives and sealants will be used only in specific
applications outlined in Chapter 2, "Table Of Sealants
and Lubricants."
WARNING
The improper use of sealants and lubricants
will cause engine malfunction or failure.
Gasket Maker P/N 646942 - Surfaces must be clean
and free of nicks, burrs, oil and grit. Apply a thin even
coat of Gasket Maker between .010 and .020 inch
thick to the surface specified in Chapter 2, "Tools,
Equipment, Sealants and Lubricants."
Gasket Maker is an easily workable tacky gel which
can be extruded onto one side of a flange surface from
a tube and evenly spread. Small parts can be covered
adequately by pressing them into a saturated polyester
urethane sponge or by roll coating them with a short
nap roller. Once Gasket Maker has been applied
evenly torque assembly into place. Excess material
can be cleaned by wiping with chlorinated solvent.
Material on hands can be cleaned with waterless
mechanics hand soap followed by soap and water.
NOTE…
TCM general purpose primer P/N 653160 must be
used for surface preparation before applying Gasket
Maker at the engine nose seal area.
4-7 INSTALLATION OF
GASKETS
All gaskets must be new, of the proper material and
visually inspected prior to installation.
Following visual inspection, if the gasket shows any
indication of gouges, nicks, cuts or bend and fatigue
marks replace with a new manufacturer specified
gasket.
Gasket surfaces must be clean and free of nicks, burrs,
oil and grit. Apply a thin coat of TCM Gasket Sealant
P/N #642188-1 to both sides of gasket unless
otherwise specified. See Chapter 2, "Tools,
Equipment, Sealants and Lubricants," for application
of gasket sealant. Once TCM Gasket Sealant has been
applied install gasket. Install assembly and evenly
torque hardware to specified value. This will prevent
over stressing gasket.
WARNING
Gaskets and components must be properly
positioned, hardware torqued and safetied as
required during assembly to prevent oil loss.
4-7
Chapter 4
INTENTIONALLY
LEFT
BLANK
4-8
Chapter 5
CHAPTER 5
RECIPROCATING ENGINE OVERHAUL
SECTION
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-14
5-15
5-16
5-17
5-18
5-19
5-20
5-21
5-22
5-23
5-24
PAGE
General ...................................................................................... 5-2
Engine Removal Instructions ..................................................... 5-2
Preliminary Cleaning ................................................................ 5-3
Extent of Disassembly ............................................................... 5-3
Parts to be Discarded ................................................................. 5-4
100% Replacement Parts ........................................................... 5-4
General Cleaning ....................................................................... 5-5
Visual Inspection ....................................................................... 5-6
Magnetic Particle Inspection...................................................... 5-6
Crankshaft Ultrasonic Inspection Procedure ............................. 5-7
Cylinder Barrel Ultrasonic Inspection Procedure ...................... 5-7
Fluorescent Penetrant Inspection .............................................. 5-7
Dimensional Inspection ............................................................. 5-7
Dimensional Limits ................................................................... 5-7
Original Dimensions ................................................................. 5-8
Parts Limits ............................................................................... 5-8
Authorized Oversize and Authorized Undersize Parts............... 5-8
Protective Coating ..................................................................... 5-8
Application Of Accelagold ....................................................... 5-8
Enamel Coatings ....................................................................... 5-8
Helical Coil Insert Replacement ............................................... 5-9
Stud Replacement ...................................................................... 5-11
New Parts .................................................................................. 5-11
Torque Applications................................................................... 5-11
FIGURE
5-1
5-2
PAGE
Installation Of Typical Helical Coil Insert ................................ 5-9
Standard and Oversize Stud Identification ................................ 5-10
TABLE
5-1
5-1A
5-2
5-3
5-4
5-5
PAGE
Bolt, Nut and Screw Torques .................................................... 5-12
Driving Stud Torques................................................................. 5-12
Pipe Plug Torques ..................................................................... 5-12
Torque Specifications For Fittings............................................. 5-12
Torque Specifications For Hose Fittings.................................... 5-13
Specific Torques ........................................................................ 5-14
5-1
Chapter 5
5-1 GENERAL
WARNING
Use only parts meeting the engine type design.
Prior to engine removal, using a differential pressure
gage perform the following leak check on each
cylinder. Record findings.
LEAK CHECK
This check serves as an identifier for conditions
which may not be detectable by visual inspection.
1. Position the piston as close to bottom dead
center on the compression stroke as possible,
insuring that the intake valve remains closed to
allow the cylinder to hold pressure.
With the compression tester connected, apply 5 PSI
to the cylinder.
WARNING
It will be necessary to hold the propeller
stationary while pressure is applied to the
cylinder. Use extreme caution to prevent injury to
personnel or damage to equipment.
WARNING
During pressurization of cylinders do not stand
or allow anyone else to stand in the propeller arc
area.
3. Increase the pressure slowly to a maximum
value of 80 PSI. Saturate the entire cylinder
assembly with a soap and water solution.
Optional airframe manufacturer accessories and
various engine components that obstruct engine
removal must also be disassembled from the engine
and airframe. For airframe manufacturer supplied
accessory removal and airframe to engine
disconnection consult the appropriate airframe
manufacturer's instructions.
Chapter 5 contains disassembly of the engine.
Chapters 6 through 16 contain overhaul information
for each of the engine systems. Use Chapter 5 to
completely disassemble engine and Chapters 7
through 18 to perform the remaining cleaning,
inspection,
repair
and
replacement
and
sub-assembly. Chapter 19 contains final engine
assembly procedures. Chapter 20 contains post
overhaul adjustment and test procedures.
As the aircraft engine is being overhauled all engine
parts and accessories must be overhauled. All engine
parts and accessories must conform with the engine
and accessory manufacturer's specifications after
overhaul prior to re-installation on the engine. See
the accessory manufacturer's overhaul instructions
for accessories supplied by manufacturers other than
Teledyne Continental Motors.
During Major Overhaul of Teledyne Continental
Motors aircraft engines, all parts and components
must conform with the manufacturer's new
specifications or be replaced. See Section 5-16,
"New Parts," for further information.
5-2 Engine Removal Instructions
As each part is disconnected and removed it must be
identified. Photographs can be helpful for orientation
of parts and components during engine re-assembly.
NOTE…
4. Inspect the complete cylinder for leakage.
Leakage will be indicated by an accumulation of
bubbles.
If the engine is being removed to be placed in
storage, prior to engine removal, accomplish the
steps listed in the chapter on "Indefinite Storage," of
the appropriate Maintenance Manual.
5. After complete cylinder inspection, relieve
cylinder pressure and remove compression
tester.
1. Insure all electrical switches, circuit breakers,
ignition switches and fuel selector valves are in
the OFF position.
6. Perform this inspection on each cylinder.
2. Disconnect battery ground cable or strap.
3. Disconnect the starter cable.
5-2
Chapter 5
4. Remove all cowling and nacelle access panels
that obstruct engine removal in accordance with
the airframe manufacturer's instructions.
11. Remove engine mount to airframe attaching
hardware in accordance with the airframe
manufacturer's instructions.
5. Remove the oil sump drain plug and washer. See
Figure 6-13, "Oil Sump." Completely drain oil
from engine and replace plug and washer.
NOTE…
6. Disconnect and tag the engine wiring bundles
and other connections from the following
components in accordance with the airframe
manufacturer's instructions.
a. Magneto ground terminal leads, retard
terminal leads, sensor unit lead
b. Alternator
c. Pneumatic pump
d. Tach drive
e. Oil temperature connection
f. Cylinder head temperature connections
g. Exhaust gas temperature connection
h. Remove all wiring bundle attaching clamps
and hardware. Route wiring bundle clear of
engine
i. Miscellaneous airframe accessories
7. Disconnect the throttle and mixture control in
accordance with the airframe manufacturer's
instructions.
8. Remove manifold pressure gage line and
airframe fuel supply hoses in accordance with
the airframe manufacturer's instructions.
Properly cap off lines and connections to
prevent fuel spillage and the admittance of
debris.
9. Removal of the exhaust system may be
necessary prior to engine removal. See the
applicable airframe manufacturer's instructions.
CAUTION…
Place a suitable stand under the aircraft tail at the
proper load bearing area before removing the
engine to prevent airframe damage due to the
aircraft tail dropping.
10. Attach an engine hoist to the engine. The engine
hoist must be attached to the engine lifting eyes
only. Extend the hoist relieving engine weight
from the engine mounts.
Hoist the engine slowly making sure all wiring,
lines, hoses and connections have been properly
disconnected. Do not bump or drop engine.
12. Install the engine on an engine stand,
transportation dolly or engine shipping container
base as applicable. Install protective covers on
all open lines and fittings. Do not use tape or
plugs inside the lines or fittings.
5-3 PRELIMINARY CLEANING
Clean engine exterior by spraying or brushing with a
solvent used for general cleaning of engine parts.
Remove caked dirt on bolt heads and nuts. At the
same time remove the oil sump drain plug and drain
any remaining oil.
WARNING
Oil must be caught in an approved container
and disposed of properly.
CAUTION…
Do not use any alkaline cleaning solutions for
external engine pre-cleaning, these solutions will
remove the "alodized" finish of aluminum parts.
5-4 EXTENT OF DISASSEMBLY
Exploded parts illustrations used in the engine
disassembly and system chapters are similar to those
used in the parts catalog. Use the illustrations along
with the written procedures to disassemble the
engine, systems and components. Disassemble the
engine systems and components to the extent
specified in the written procedure of the applicable
engine system chapter.
WARNING
Do not attempt to identify components using the
illustrations in this manual. Component
identification must be accomplished using the
nomenclature and part numbers in the related
parts catalog or contact the factory.
5-3
Chapter 5
5-5 PARTS TO BE DISCARDED
Discard all parts listed in Section 5-6, "100%
Replacement Parts" and/or Service Bulletin M97-6,
“Mandatory Replacement Parts,” in such a manner
they will not be used again inadvertently.
Care must be taken in removing gaskets from
aluminum parts by scraping. Such removal should be
delayed until the part is to be cleaned.
5-6
100 PERCENT(%)
REPLACEMENT PARTS.
At assembly, during maintenance, preventive
maintenance and engine or component overhaul
replace all gaskets, seals, packings, hoses, "O" rings,
cotter pins, retaining rings (snap rings), safety wire,
self locking fasteners (including exhaust manifold
nuts) and lock washers with new parts.
Engine mounted accessories not manufactured by
TCM must be overhauled at engine overhaul and
maintained in accordance with the instructions
provided by the manufacturer.
Do not re-use any fasteners that are worn, deformed, or
are designed to be used only once. Do not replate
any cadmium plated fasteners or washers. If the
cadmium plating has been removed discard the item
and replace it with a new part.
At engine overhaul in addition to the previously
listed items, the following listed parts must be
discarded and replaced with new parts.
NOTE…
If for any reasons hydraulic valve tappets are
removed for inspection before the overhaul period
has been reached, they must be placed back in the
same location from which they were removed.
1. Hydraulic valve lifters (tappets)
2. Bearings: connecting rod, crankshaft main
and thrust, needle, ball, and roller
3. Bushings: rocker arm, connecting rod,
counter weight and crankshaft counterweight blade
4. Counterweight pins, retaining plates and
snap rings
5. Camshaft gear bolts
6. Connecting rod forging number 626119,
TCM P/N’s 646320 and 646321 with beam
5-4
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
width less than .625 inches. Reference TCM
CSB96-13.
Camshaft gear bolts
Crankshaft gear bolts
Woodruff keys
Connecting rod bolts and nuts
Magneto drive rubber bushings
Exhaust valves
Roto-coils, exhaust valves
Intake and exhaust valve keepers
Inner and outer valve springs
Piston pins
Piston rings
Pistons
Rocker shafts
Rockers shaft thrust washers
Crankcase Through Bolts
Cylinder deck stud nuts and through bolt
nuts
Exhaust clamps
Cold Start primer diverter valves
Alternator drive coupling rubber bushings
Turbocharger oil supply and return check
valves
Replace 649470, 649471, 652669, 652670
oil suction screens with 653658 oil suction
screen
Replace oil pump gears in accordance with
TCM Service Bulletin SB 96-4 latest
revision
Ignition system wiring harness
Spark plugs
Alternator and air conditioning drive belts
5-7 GENERAL CLEANING
NOTE…
Parts listed in Section 5-6, "100% Replacement
Parts," must be replaced and therefore do not require
cleaning.
WARNING
During any cleaning process always follow the
cleaning material manufacturer's instructions for
use, and Material Safety Data Sheets for safety
precautions and disposal information.
Chapter 5
Engine components must be thoroughly cleaned so
they can be properly inspected. All surfaces must be
protected from corrosion after cleaning by rinsing
with a petroleum base solvent and applying a coat of
clean 50 weight aviation engine oil.
CAUTION…
Cleaning methods other than the following may be
destructive to engine parts and must not be used.
Aluminum Alloy Parts: Degrease aluminum alloy
components by spraying or brushing with any
fortified mineral spirit solvent. Heavy grease or dirt
deposits can be cleaned effectively by allowing parts
to soak in this solvent for a short period of time.
Carbon deposits and gum (oil varnish) may be
removed easily by immersing the part in a hot bath
of an inhibited, mild alkaline cleaning solution.
Immersion time should be only as long as necessary
to remove the deposit. Give special attention to
cleaning studs, tapped holes and drilled holes.
Caution must be exercised when cleaning aluminum
alloy parts using any alkaline cleaning solutions.
Immediately after removing soaked parts from
inhibited, mild alkaline bath or hot soapy water,
remove all traces of the alkaline by spraying the
parts with a jet of steam, or brushing vigorously with
a mineral spirit solvent. Cleaned parts may be dried
by a jet of dry, compressed air to remove all solvent
liquids.
CAUTION…
When using alkaline cleaning solutions, the cleaning
solution manufacturer's usage, safety data and
disposal information must be strictly followed.
Alkaline etching solutions must not be used.
CAUTION…
All alkaline residues must be removed from crevices,
recesses and holes to prevent the formation of a
foaming emulsion in the engine lubrication oil after
reassembly. If Accelagold surface was removed by
the cleaning process it must be re-applied in
accordance with the procedure in Section 5-19,
"Application Of Accelagold." [Accelagold is
manufactured by Turco® Products Inc.]
CAUTION…
Alkaline cleaning solutions will cause corrosion to
metals if not completely removed.
Carbon solvent should be employed only when
carbon deposits are too hard or thick for removal by
other solvents.
No polishing compound, abrasive paste or powder is
needed for cleaning engine parts. Do not scrape parts
or use wire brushes, sandpaper, abrasive cloth or
abrasive wheels. Scratches resulting from such
methods allow concentrated stress at the scratch and
may cause fatigue failure.
Blasting techniques can be employed to remove hard
carbon deposits if suitable equipment is available.
Suitable types of grit for dry blasting are plastic
pellets and processed natural materials such as wheat
grains and crushed fruit pits or shells. Air pressure
must be adjusted to the lowest setting that will
produce the desired cleaning action. Small holes and
machine finished surfaces must be protected from
the blast by seals and covers.
5-5
Chapter 5
WARNING
All cleaning material must be removed from
parts and components after cleaning.
CAUTION…
Do not use sand, metal grit or glass beads for any
type of cleaning. If water mixed degreasing solutions
containing caustic compounds or soap are used to
clean aluminum alloy components they must be
thoroughly and completely rinsed with clear boiling
water or steam to prevent corrosion.
CASTINGS: Gasket surfaces must be thoroughly
cleaned with a suitable hydrocarbon solvent such as
naphtha, methyl ethyl keytone (MEK) or
trichloroethylene (TCE) to remove dirt, oil and
grease. Surfaces must be clean, dry and free of all
old gasket material before applying new gaskets.
SMALL STEEL PARTS: Degrease steel parts by
spraying or brushing with mineral spirit solvent.
Heavy grease or dirt deposits can be cleaned
effectively by allowing the part to soak in this
solvent for a short period of time.
NOTE…
See Chapters 7 through 18 for specific individual
system component and part cleaning instructions.
5-8 VISUAL INSPECTION
All engine parts except those to be replaced 100%
must be inspected visually with at least a 10 X
(power) magnifying glass under good light for
surface damage such as nicks, dents, deep scratches,
visible cracks, distortion, burned areas, pitting,
transfer of metal, corrosion, erosion and removal of
enamel coating. Visual inspection should also
determine the need for further cleaning of obscure
areas. Inspect all studs for bending, looseness or
partial removal. Inspect all threaded parts for nicks
and other damage to the screw threads. After visual
inspection place the engine parts in three groups:
apparently serviceable parts, repairable parts and
parts to be discarded.
5-6
NOTE...See Chapters 7 through 18 for specific
individual system components and part visual
inspection instructions.
5-9 MAGNETIC PARTICLE
INSPECTION
CAUTION…
Before magnetic particle inspection of any part, it
must be completely cleaned and free of dirt, carbon,
varnish, gum and paint. Plug small holes leading to
obscure cavities with tight-fitting wood plugs or with
a hard grease which is soluble in lubricating oil.
This will prevent particles from lodging in places
where they would be difficult to remove and places
not subject to visual inspection. After magnetic
particle inspection remove all such plugs and clean
the part thoroughly in solvent. Dry the part with
compressed
air.
Check
for
complete
demagnetization.
Magnetic particle inspection must be conducted on
all ferrous parts.
Where magnetic particle inspection is required, it
must be performed in accordance with ASTM E
1444. The wet continuous method utilizing full wave
rectified altemating current and fluorescent particles
is required.
ACCEPT / REJECT CRITERIA
Rejectable discontinuities are any of the following:
fatigue cracks, forming cracks, grinding and heat
treat cracks, embrittlement cracks, seams, laps, burst.
Parts which contain linear indications which cannot
be reworked or indications which break into comers,
edges, holes, thread roots, fillets, gear tooth roots or
keyways must be rejected.
The particular magnetic particle manufacturer's
information regarding use, safety data and disposal
must be followed carefully.
Chapter 5
5-10 CRANKSHAFT
ULTRASONIC
INSPECTION
PROCEDURE
The crankshaft must be ultrasonic inspected in
accordance with TCM MHS 200 by individuals
certificated to perform this detailed inspection. For
approved inspection locations contact TCM at: (334)
438-3411.
5-11 CYLINDER BARREL
ULTRASONIC INSPECTION
PROCEDURE
Cylinders must be ultrasonic inspected in accordance
with TCM MHS 198 by individuals certificated to
perform this detailed inspection. For approved
inspection locations contact TCM at: (334) 4383411.
5-12
FLUORESCENT
PENETRANT INSPECTION
Inspection by the fluorescent penetrant method must
be conducted on all non-ferrous metal parts.
Where fluorescent penetrant inspection is required, it
must be performed in accordance with ASTM E
1417. Specific process procedures are referenced in
ASTM E 1208, E 1209, or E 1219. The penetrant
method used must be Type I (fluorescent), Method
A, B, C or D.
ACCEPT / REJECT CRITERIA
Rejectable discontinuities are any of the following:
fatigue cracks, forming cracks, grinding and heat
treat cracks, embrittlement cracks, seams, laps, burst.
Parts which contain linear indications which cannot
be reworked or indications which break into comers,
edges, holes, thread roots, fillets, gear tooth roots or
keyways must be rejected.
NOTE…
The particular fluorescent penetrant manufacturer's
information regarding use, safety data and disposal
must be followed carefully.
5-13 DIMENSIONAL
INSPECTION
Inspect for manufacturer specified fit with mating
parts by comparative linear measurements and
alignment measurement using standard precision
measuring instruments.
5-14
DIMENSIONAL LIMITS
After comparative measurement of mating parts and
determination of running clearance refer to the limits
section related to the part. Limits under the column
heading New Parts are manufacturing limits.
Clearances in the New Parts column apply to
mating parts. Example: Check inside and outside
diameters of mating part surfaces. Take the recorded
dimensions and subtract the smaller from the larger.
If the remainder falls within the New Parts
minimum and maximum clearance the part may be
re-used during overhaul provided it conforms with
all other inspection requirements. Oversize parts are
supplied in some instances to permit conformity to
this requirement. See individual component or
system sections as applicable for limits and fits.
5-15
ORIGINAL DIMENSIONS
Although comparative measurements of mating parts
will determine the serviceability of the fit it may be
difficult to determine which part has worn. In some
instances (e.g., main journals in new bearing inserts)
accurate dimensional measurements of fit are not
always possible. While no limits of wear on critical
dimensions have been assigned to specific parts it is
helpful in determining wear to know the original
dimensions. Therefore, consult the manufacturing
limits, "Critical New Parts Dimensions," in each
individual system chapter when the serviceability of
a specific part is in doubt.
See Chapters 7 through 18 for specific individual
system components and part fluorescent penetrant
inspection instructions.
5-7
Chapter 5
5-16
PARTS LIMITS
TCM provides parts dimensions and assembly
clearances in its publications which are considered
essential to perform an overhaul of its engines.
These values are termed "New Parts Limits." Values
are taken from production drawings in effect at the
time of publication. TCM also provides a list of
items that must be replaced at overhaul. See section
5-6, "100% Replacement Parts."
WARNING
Service limits must not be used when performing
major overhaul of the engine.
5-17 AUTHORIZED OVERSIZE
AND AUTHORIZED
UNDERSIZE PARTS
Replacement authorized oversize (AO) or authorized
undersize (AU) parts must be used with the proper
AO and AU mating parts. Example: Use .015
oversize piston and piston rings with .015 oversize
cylinder assembly.
5-18 PROTECTIVE COATING
The manufacturer protects all aluminum alloy
castings, sheet metal and tubing from corrosion by
treating all surfaces of the parts with Accelagold
aluminum conversion coating. [Accelagold is
manufactured by Turco Products, Inc.] For sales and
service contact Elf Atochem N.A. Turco® Products
Div., P.O. Box 195, State Route 95, West Marion
Ohio, 43302; (215) 419-5376.
5-19
APPLICATION OF
ACCELAGOLD
After any machining or repair operation aluminum
surfaces must be treated with an aluminum
conversion coating. If the original aluminum
5-8
conversion coating has been removed or
deteriorated, it must be re-applied. The application
of Accelagold solution must be performed in
accordance with the manufacturer's Technical Data
Bulletin
Number
108-31
TURCOAT®)
ACCELAGOLD ALUMINUM CONVERSION
COATING.
Wrought or die cast smooth surface parts such as
valve rocker covers and intake tubes are "tumble
blasted" prior to machining to roughen surfaces
before treatment. Tumble Blasting must not be
applied at overhaul on parts with machined surfaces.
CAUTION…
Do not use enamel paint or primer for internal
parts. The paint or primer may flake or break off
during engine run and contaminate lubricating oil.
5-20 ENAMEL COATINGS
Ferrous parts when painted with gold enamel must
be baked with infra-red equipment for 15 minutes at
275-300°F following the application of each coat.
Magnesium parts must be pickled and primed before
painting. Then baked with infra-red equipment for
15 minutes or oven dry 60 minutes at 275°-300°
following application of each coat of enamel.
NOTE…
If a part which was originally alodized is to be
refinished with enamel it is not necessary to apply
zinc chromate primer unless surface areas have been
completely stripped of Accelagold.
CAUTION…
Before application of primer and enamel to a part
carefully mask all connection joints and mating
surfaces. No primer or enamel is permissible on
interior surfaces of any parts contacted by engine
lubricating oil after assembly.
Chapter 5
5-21 HELICAL COIL INSERT
REPLACEMENT
Helical coil inserts are installed at the factory in
various tapped holes of some engine components.
Stainless steel helical coil inserts of special design
are installed in all spark plug holes. Any of these
inserts may be replaced if damaged. Tools, inserts
and information are available through HeliCoil®,
Emhart Fastening Teknologies. Contact HeliCoil®
Applications Engineering or customer service at:
(203) 924-4737 for local distributor information.
The manufacturer's Bulletins 959A, 995, 943, T4000
and 1000 latest revisions list manual and powerdriven installing tools, tang break-off tools, special
taps, plug gauges and tap/drill information. Helical
coil inserts are available in both National Course and
National Fine series in lengths equal to 1, 1 -1 /2 and
2 times nominal diameter and in pipe thread sizes.
They are made of either carbon steel, phosphor
bronze or stainless steel, as specified by part
number. They are supplied with or without a notch
above the driving tang. The notch is provided to
facilitate breaking off the tang in open holes.
Helical coil inserts are helical coils of wire with a
diamond-shaped cross section forming both a male
and female thread. When compressed into a special
tapped hole at the widest part of the wire, between
male and female threads, the diameter of the insert is
equal to the nominal screw size. The special
finishing taps size the casting hole so the pitch
diameter of the female thread of the installed insert
conforms to Class 3 fit with standard bolt threads or
class 4 (tight) fit with standard-size studs. The
difference in fit is due to a difference in pitch
diameters of bolts and studs. Only one set of helical
coil special taps is required for installation of these
inserts in both bolt holes and stud holes. Tap drilling
depths and tapping depth for helical coil inserts to be
installed in blind holes should conform to the
recommendations relative to inserts of length equal
to 2 times nominal diameter, as tabulated in the
manufacturer's Bulletin Numbers 1000 and T4000
latest revision. Helical coil tap drills and special taps
must be run in perpendicular to the machined surface
of the casting. Drilling must be done in a drill press
after the casting is firmly supported, clamped and
alignment checked. The tap will tend to follow the
drilled hole. For drilling and tapping aluminum alloy
castings use a commercial grade cutting lubrication
oil to prevent overheating of the metal and tearing of
the thread.
FIGURE 5-1. INSTALLATION TYPICAL HELICAL COIL INSERT
5-9
Chapter 5
5-21 HELICAL COIL INSERT
REPLACEMENT (cont’d)
To remove a damaged helical coil insert use the
proper size of extracting tool for the nominal thread
size. Tap it into the insert so the sharp edges get a
good bite, then turn the tool to the left, and back out
the helical coil until it is free. To install new insert in
a properly tapped hole, after blowing out all liquid
and chips, slide it over the slotted end of the driving
mandrel of the proper size installing tool, and
engage the driving tang (bent end) of the helical coil
in the mandrel slot; then, wind the insert slowly into
the tapped hole. See Figure 5-1, "Installing Typical
Helical Insert." The outer end of the insert must lie
within the first full thread of the hole. Break off the
driving tang of a notched helical coil by bending
back and forth across the hole with long-nose pliers,
or with a special tang break-off tool.
After helical coil replacement the remaining wall
thickness (edge distance) must not be less than one
half the helical coil diameter or .08 minimum
whichever is greater.
WARNING
The 2 and 4 o'clock cylinder deck stud positions
must not be repaired by helical coil insert
installation.
5-22
STUD REPLACEMENT
Remove damaged whole studs with a stud remover
turning slowly to avoid heating the casting. Remove
broken studs which cannot be gripped with a
standard stud extractor by drilling on center to the
correct diameter and unscrewing with a splined stud
extractor. Splined extractors and drills are usually
sold in sets. Examine the course thread end of the
damaged stud before discarding it to determine its
size. Standard studs have no marking. For oversize
stud identification, see Figure 5-2, "Standard And
Oversize Stud Identification." Clean the casting
tapped hole with solvent and blow dry with
compressed air. Then examine the thread. If it is not
torn install the next larger oversize stud. If the old
stud was of the maximum oversize or if the thread is
damaged the hole may be tapped and a helical coil
insert installed for a standard-size stud provided
sufficient stock is available.
FIGURE 5-2. STANDARD AND OVERSIZE STUD IDENTIFICATION
5-10
Chapter 5
Coat the new stud's course thread with High
Strength Adhesive P/N 646941 if the hole is blind or
if the hole goes through to a cavity subject to
leakage. Drive the new stud with a tee handle stud
driver. Turn it slowly and compare the torque values
listed in the Table 5-2, "General Use Torques."
Drive the stud in until it projects a distance equal to
the specified setting height. See stud setting heights
in the applicable component or system section.
5-23
NEW PARTS
Parts which require protection from atmospheric
dust and moisture are wrapped or boxed
individually. These parts must not be unpacked until
they are to be installed. This includes precision
bearing inserts and anti-friction bearings. Check new
parts on receipt for transit damage. All parts must be
clean and lubricated as specified prior to installation.
Refer to the L/TSI0-360-RB Parts Catalog, Form
X30597A Supplement 1, for part number of the
complete gasket set, the main bearing set and the
piston ring set. Refer to Chapter 2, "Tools,
Equipment, Sealants And Lubricants," for approved
products, all of which must be on hand when work is
started. Use only new shakeproof or split lock
washers, tab washers, elastic stop nuts, cotter pins
and corrosion-resistant lockwire. Refer to Section 56, "100% Replacement Parts," before assembly.
Measure clearances of running parts as they are
assembled and compare with clearances listed in the
applicable component or system chapter. During
major engine overhaul use only NEW PARTS
LIMITS. See Section 5-16, "New Parts And Service
Limits."
5-24 TORQUE APPLICATIONS
Prior to torquing any hardware apply the specified
lubricants in accordance with Chapter 2.
The accuracy of any torque indicating wrench
depends on a smooth application of force and
current calibration traceable to the National Bureau
of Standards. If a nut slot cannot be aligned with a
cotter pin hole within the specified limits, substitute
another serviceable nut. If the cotter pin hole in stud
lies beyond the nut slots, when the nut has been
torqued properly check stud for proper installation or
backing out. Check part to see if it has been reduced
in thickness. Check to insure nut and washer are
correct parts for that location. The situation must be
corrected by whatever replacement is indicated by
inspection.
NOTE...
See Tables 5-2 through 5-6 on the following pages
for, "Bolt, Nut and Screw Torques, Driving Stud
Torques, Pipe Plug, Torques, Torque Specifications
For Fittings, Torque Specifications for Hose Fittings
and Specific Torques."
The engine overhaul must be performed in a clean
dust free environment, and engine sub-assemblies
must be covered whenever they are not in the
process of cleaning, inspection, repair or assembly.
5-11
Chapter 5
GENERAL USE TORQUES
TABLE 5-1. Bolt, Nut and Screw Torques
SIZE
INCH POUNDS
FOOT POUNDS
8-32
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-20
17.5-22.5
21.0-25.0
36.0-50.0
75.0-85.0
90.0-110
155-175
180-220
220-260
275-325
−
400-450
550-600
1.5-1.9
1.7-2.0
3.0-4.2
6.3-7.1
7.5-9.2
12.9-14.6
15.0-18.3
18.3-21.7
22.9-27.1
−
33.3-37.5
45.8-50.0
NOTE…
Torque loads listed are for use with oil on threads as
specified in Chapter 2.
SIZE
5/16-24
5/16-24
3/8-24
3/8-24
7/16-20
7/16-20
7/16-24
9/16-18
9/16-18
3/4-16
3/4-16
7/8-14
7/8-14
NOTE…
Stud driving torques apply when studs are coated with
lubricant or sealer as specified in Chapter 2.
TABLE 5-2. PIPE PLUG TORQUES
SIZE
1 /8-27
1/4-18
3/8-18
1/2-14
3/4-14
INCH POUNDS
60-80
130-150
185-215
255-285
310-350
FOOT POUNDS
5.0-6.7
10.8-12.5
15.4-18.0
21.3-23.8
25.8-29.2
TABLE 5-3. TORQUE SPECIFICATIONS FOR FITTINGS
FITTING AND MATERIAL
TUBE O.D.
INCH POUNDS
#2 (Brass/Aluminum)
.125
15-30
#2 (Steel)
.125
15-50
#3 (Brass/Aluminum)
.188
40-65
#3 (Steel)
.188
50-90
#4 (Brass/Aluminum)
.250
60-80
(Steel)
.250
70-120
#4 (Steel)
.190
60-80
#6 (Brass/Aluminum)
.375
75-125
#6 (Steel)
.375
90-150
#8 (Brass/Aluminum)
.500
150-250
#8 (Steel)
.500
135-250
#10 (Brass/Aluminum)
.625
200-350
#10 (Steel)
.625
300-400
See notes on page 5-18.
5-12
TABLE 5-1.A DRIVING STUD TORQUES
SIZE
INCH POUNDS FOOT POUNDS
1/4-20
50-70
4.2-5.8
5/16-18
100-150
8.3-12.5
3/8-16
200-275
16.7-22.9
7/16-14
300-425
25.0-35.4
Chapter 5
TABLE 5-4. TORQUE SPECIFICATIONS FOR HOSE FITTINGS
HOSE SIZE
THREAD SIZE
FITTING MATERIAL
INCH POUNDS
#2
(5/16-24)
Hose End Fitting To Brass/Allum. Fitting
Hose End Fitting To Steel Fitting
50-80
75-120
#3
(3/8-24)
Hose End Fitting To Brass/Allum. Fitting
Hose End Fitting To Steel Fitting
70-105
95-140
#4
(7/16-20)
Hose End Fitting To Brass/Allum. Fitting
Hose End Fitting To Steel Fitting
100-140
135-190
#5
(1/2-20)
Hose End Fitting To Brass/Allum. Fitting
Hose End Fitting To Steel Fitting
130-180
170-240
#6
(9/16-18)
Hose End Fitting To Brass/Allum. Fitting
Hose End Fitting To Steel Fitting
150-195
215-280
#8
(3/4-16)
Hose End Fitting To Brass/Allum. Fitting
Hose End Fitting To Steel Fitting
270-350
470-550
# 10
(7/8-14)
Hose End Fitting To Brass/Allum. Fitting
Hose End Fitting To Steel Fitting
360-430
620-745
# 12
(1-1/16-12)
Hose End Fitting To Brass/Allum. Fitting
Hose End Fitting To Steel Fitting
460-550
855-1055
WARNING
Failure to lubricate threads, apply the specific torque and follow the specific torquing
procedure may result in damage and subsequent engine malfunction or failure.
5-13
Chapter 5
TABLE 5-5. SPECIFIC TORQUES
LOCATION and
HARDWARE
Connecting Rod and Cap
Camshaft Rear Gear
Crankshaft Gear
Crankcase Backbone
Crankcase Nose
Crankcase Nose 1-3 -5 Side
Crankcase Rear Above Crankshaft
Crankcase Rear Below Crankshaft
Crankcase Rear Below Crankshaft
Engine Mount Brackets
Magneto Drive Gear Shaft
Crankshaft Oil Seal Retainer Plate
Cover Camshaft
Cylinder To Crankcase
Rocker Arm Shaft To Cylinder
Rocker Cover To Cylinder
Oil Pump Cover To Accy. Case
Accessory Case To Crankcase
Tach Drive Adapter Cover To Acc. Case
Oil Suction Tube To Oil Sump
Oil Sump To Crankcase and Acc.
Case
Oil Sump
Oil Screen, Scavenge Oil
Oil Filter Adapter To Acc. Case
Oil Filter
Oil Pressure Relief Valve Housing To Acc.
Case
Oil temperature control valve
Oil Cooler to Plate
Starter Adapter To Acc. Case
Starter to Adapter
Spring to starter clutch
5-14
TORQUE
INCH
POUNDS
FOOT
POUNDS
SIZE
QTY.
Nut
Bolt
Bolt
Nut
Nut
Nut
Nut
Nut
Oil Cooler
Adapt. Nut
Oil Cooler
Adapt. Nut
Nut
Nut
Bolt
Bolt
Nut
Nut
Nut
Screw
Bolt
Nut
Bolt
Self Locking
Nut
Tube
Nut
3/8 - 24
5/16 - 24
5/16 - 24
1/4 - 28
7/16 - 20
1/4 - 28
7/16-20
7/16 - 20
7/16 - 20
12
4
4
11
4
2
2
1
1
400 - 475
240 - 260
240 - 260
100 - 125
440 - 460
100 - 125
440 - 460
440 - 460
440 - 460
33.3 - 39.6
20.0 - 21.7
20.0 - 21.7
8.3 - 10.4
36.6 - 38
38.3 - 10.4
36.6 - 38.3
36.6 - 38.3
36.6 - 38.3
3/8 - 24
1
275 - 325
22.9 - 27.0
3/8 - 24
5/16 - 24
10 - 24
1/4 - 20
7/16 - 20
3/8
1/4 - 28
1/4 - 20
1/4 - 20
5/16 - 24
5/16 - 24
1/4 - 28
11
2
4
2
12
36
24
32
4
7
5
3
275 - 325
190 - 210
21 - 25
75 - 85
590-610
440 - 460
110 - 120
55 - 65
75 - 85
180 - 220
180 - 220
90-110
22.9 - 27.0
15.8 - 17.5
1.7 - 2.1
6.3 - 7.1
49.1 - 50.8
36.6 - 38.3
9.2 - 10.0
4.6 - 5.4
6.3 - 7.1
15.0 - 18.3
15.0 - 18.3
7.5 - 9.2
1/4 - 28
1
14
310 - 350
90 - 110
25.8 - 29.1
7.5 - 9.2
Plug
Screen
Nut
Filter
Housing
5/8 - 18
1.00 - 18
5/16 - 24
3/4 - 16
7/8 - 16
1
1
3
1
1
190 - 210
200 - 210
180 - 220
192 - 216
190 - 210
15.8 - 17.5
16.7 - 17.5
15.0 - 18.3
16.0 - 18.0
15.8 - 17.5
1"-14NS3A
THD
1/4 - 20
5/16 - 24
5/16 - 24
3/8 - 24
.25 - 20
1
440 - 460
36.7 - 38.3
8
3
2
2
1
100 - 110
155 - 175
155 - 175
200 - 220
75 - 85
8.3 - 9.2
12.9 - 14.6
12.9 - 14.6
16.7 - 18.3
6.3 - 7.1
Screw
Bolt
Nut
Nut
Screw,
Special
Chapter 5
TABLE 5-5. SPECIFIC TORQUES (Cont’d)
TORQUE
LOCATION and
HARDWARE
Scavenge pump cover to scavenge pump
housing
Sheave to starter shaftgear
Alternator To Acc. Case
Alternator Adjusting Bracket To
Alternator Mount Bracket
Alternator Adjusting Bracket
Air Throttle Adapter to Fuel Servo
Induction Manifold Flange To
Cylinder
Fuel Pump To Crankcase
Fuel Servo To Intake Manifold
Aftercooler To Mount Bracket
Fuel Nozzle To Cylinder
Fuel Line To Fuel Nozzle
Fuel Line To Manifold Valve
Nut Union To Manifold Valve
Magneto To Acc. Case
Harness To Magneto
Spark Plug To Cylinder
Harness Lead To Spark Plug
Turbocharger Oil Inlet Adapter
Turbocharger Oil Outlet Adapter
Turbocharger Mount Brackets To
Aftercooler Mount Bracket
Mount Bracket To Turbocharger
Turbine Housing Flange To Exhaust
Manifold
Wastegate To Exhaust Manifold By-Pass
Flange
Exhaust Manifold Flange To Cylinder
INCH
POUNDS
FOOT
POUNDS
SIZE
QTY.
Screw
.25 - 20
6
75 - 85
6.3 - 7.1
Bolt
Nut
Bolt/Nut
7/16 - 20
5/16 - 24
3/8 - 24
3
1
600 - 650
180 - 220
200 - 275
50.0 - 55.2
15.0 - 18.3
16.7 - 22.9
Nut
Screw
Nut
3/8 - 24
1/4 - 20
5/16 - 24
1
4
12
200 - 275
75 - 85
50 - 70
16.7 - 22.9
6.3 - 7.1
4.2 - 5.8
Nut
Screw
Nut
Nozzle
Nut
Nut
Nut
Nut
Screw
Plug
Nut
Screw
Screw
Screw/Nut
5/16 - 24
5/16 - 18
1/4 - 20
.125 - 27
.312 - 32
.375 - 24
.375 - 24
5/16 - 24
10 - 32
18 mm
3/4 - 20
5/16 - 18
5/16 - 24
5/16 - 24
4
4
3
6
6
6
2
4
6
12
12
2
2
3
180 - 220
155 - 175
75 - 85
55 - 65
40 - 45
55 - 60
55 - 60
100 - 120
20 - 22
300 - 360
110 - 120
155 - 175
220 - 260
180 - 220
15.0 - 18.3
12.9 - 14.6
6.3 - 7.1
4.6 - 5.4
3.3 - 3.8
4.6 - 5.0
4.6 - 5.0
8.3 - 10.0
1.7 - 1.8
25.0 - 30.0
9.2 - 10.0
12.9 - 14.6
18.3 - 21.7
15.0 - 18.3
Bolt
Bolt/Nut
-------
3
4
155 - 175
90 - 110
12.9 - 14.6
7.5 - 9.2
Bolt/Nut
1/4 - 28
8
240 - 280
20.0 - 23.3
Nut
5/16 - 24
12
200 - 210
16.7 - 17.5
➀ Torque loads listed are for use with oil on threads. If cotter pin holes must be aligned set torque wrench at
low limit and torque nut to first hole beyond this torque. Stud driving torques apply when studs are coated with
lubricant or sealer. Do not exceed the high limit torque.
➁ Hardware requiring torque, not listed in Table Of Specific Torques, must be torqued according to general
use Torque Chart or Pipe Plugs, Hydraulic line fitting charts and Torque Specifications For Hose Fittings as
applicable.
WARNING
Failure to lubricate threads, apply the specific torque and follow the specific torquing
procedure may result in damage and subsequent engine malfunction or failure
5-15
Chapter 5
INTENTIONALLY
LEFT
BLANK
5-16
Chapter 6
CHAPTER 6
DISASSEMBLY
SECTION
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-11
6-12
6-13
6-14
6-15
6-16
6-17
FIGURE
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-10A
6-11
6-12
6-13
6-14
6-15
6-15A
6-16
6-17
6-18
6-19
PAGE
Exhaust System Removal and Disassembly .................................6-2
Ignition System Removal and Disassembly .................................6-4
Fuel Injection System Removal and Disassembly........................6-6
Induction System Removal and Disassembly...............................6-8
Compressor Mounting Components, Starter and Starter
Drive Adapter Removal................................................................6-10
Belt Driven Alternator Removal...................................................6-12
Accessory Case Mounted Alternator Removal.............................6-15
Optional Starter and Starter Adapter (TSI0-360-RB)...................6-16
Starter and Starter Adapter (LTSI0-360-RB) ...............................6-18
Accessory Case Disassembly .......................................................6-20
Oil Pump Removal .......................................................................6-23
Oil Cooler Removal......................................................................6-24
Oil Sump Removal .......................................................................6-25
Cylinder Baffling Disassembly ....................................................6-26
Cylinders and Piston Removal .....................................................6-28
Crankcase Associated Parts Removal...........................................6-30
Crankcase Disassembly and Train Removal ................................6-32
PAGE
Exhaust System ............................................................................6-3
Ignition System.............................................................................6-5
Fuel Injection System ...................................................................6-7
Induction System ..........................................................................6-9
Compressor Mounting Components, Starter and Starter
Adapter Assembly ........................................................................6-11
Belt Driven Alternator Assembly .................................................6-13
Accessory Case Mounted Alternator ............................................6-15
Optional Starter Adapter Assembly (TSI0-360-RB) ....................6-17
Starter Adapter Assembly (LTSI0-360-RB).................................6-19
Accessory Case (TSI0-360-RB) ...................................................6-21
Accessory Case (TSI0-360-RB) ...................................................6-22
Oil Pump Assembly......................................................................6-23
Oil Cooler .....................................................................................6-24
Oil Sump.......................................................................................6-25
Cylinder Baffle Assembly ............................................................6-27
Cylinder and Piston Assembly .....................................................6-29
Connecting Rod Support ..............................................................6-29
Crankcase Associated Parts ..........................................................6-31
Crankcase Attaching Parts............................................................6-33
Camshaft Assembly ......................................................................6-34
Crankshaft Assembly....................................................................6-35
6-1
Chapter 6
remove tailpipe (10), from turbocharger (21).
Discard "V" band clamp assembly (43).
6-1 EXHAUST SYSTEM
REMOVAL AND DISASSEMBLY
(See Figure 6-1)
1. Remove turbocharger to scavenge pump hoses
(57, 59), check valve (58) and fittings(60, 61).
Discard hoses (57, 59) and check valve (58).
2. At two locations, remove turbocharger oil supply
hose clamp (71), brackets (72) or (73), bolts (70),
washers (74), and nuts (75).
3. Remove turbocharger oil supply hose assembly
(53) and check valve (54). Discard hose (53) and
check valve (54).
4. Remove wastegate to controller hose assembly
(68). Discard hose (68).
5. Remove oil filter adapter to wastegate hose
assembly (64). Discard hose (64).
6. Remove bolt (24 and Nut (25). Discard Nut (25).
Loosen "V' band clamp assembly (43) and
7. Remove bolts, nuts and washers (39 through 42).
Discard nuts (42). Remove wastegate assembly
(38), gaskets (37) and tube (11). Discard gaskets
(37).
8. Remove bracket (22), bolts, nuts and washers (26,
27, 28). Discard nuts (28). Remove bolts, nuts and
washers (48, 49, 50). Discard nuts (50). Remove
turbocharger (21) and bracket (45).
9. Remove tie rod (13), two spacers (14), bolt (15),
nut (16) from left side exhaust manifold. Remove
tie rod (17), two spacers (14), bolt (15), nut (16)
from right side exhaust manifold. Loosen, remove
and discard clamp assemblies (12). Discard clamp
assemblies (12). Remove exhaust elbows (7, 8)
and remove turbo inlet manifold (9). Discard nuts
(16).
10. Remove nuts (13), right side exhaust system items
(1), (3), (5), (8) and left side exhaust system
sections (2), (4), (6) and (7). Remove exhaust
flange
gaskets
(18)
and
discard.
NOMENCLATURE FOR FIGURE 6-1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
6-2
Tee,Riser
Tee, Riser
Tee, Riser
Tee, Riser
Tee, Riser
Tee, Riser
Elbow
Elbow
Manifold
Tailpipe
Tube
Clamp
Tie Rod
Spacer
Bolt
Nut
Tie Rod
Gasket
Nut,, Exhaust
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Gasket
Turbocharger
Bracket
Clamp
Bolt
Nut
Bolt
Washer
Nut
Gasket
Adapter
Washer, Lock
Bolt
Gasket
Adapter
Washer,, Lock
Bolt
Gasket
Wastegate
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
Bolt
Bolt
Washer
Nut
Clamp
Bolt
Bracket
Bracket
Bracket
Bolt
Washer
Nut
Elbow
Reducer
Hose
Check Valve
Tee
Elbow
Hose
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
Check, Valve
Hose
Elbow
Elbow
O-Ring
Elbow
Hose
Elbow
O-Ring
Elbow
Hose
Elbow
Bolt
Clamp
Bracket
Bracket
Washer
Nut, Self Locking
Washer, Tab
Chapter 6
FIGURE 6-1. EXHAUST SYSTEM
6-3
Chapter 6
a. Remove attaching rocker cover screw and
lock washer, and remove single lead clamps
(24) (typical twelve places).
6-2 IGNITION SYSTEM
REMOVAL AND
DISASSEMBLY (See Figure 6-2.)
b. Remove ignition lead from each spark plug
(7).
1. Remove magneto pressurization system:
c. Remove two six-lead clamps (25) by
removing self-locking nut (28) and screw
(27).
a. On the 2-4-6 magneto, loosen clamp (18)
and remove clamp and hose (17) from 90°
elbow (19). Discard hose (17).
d. Cut and remove cable ties (26).
b. Remove 90° elbow (19) and bushing (20)
from the 2-4-6 magneto.
e. On each magneto, remove three screws (23)
from cable outlet plate and remove plates
from magnetos (2).
c. On the 1-3-5 magneto, loosen clamp (18)
and remove clamp and hose (16) from 90°
elbow (19). Discard hose (16).
f.
d. Remove 90° (19) and bushing (20) from the
1-3-5 magneto.
3. Disconnect ground terminal kit from magnetos
(2) in accordance with airframe manufacturer's
instructions.
e. Loosen clamps (18) and remove hose (15),
filter (14), reducer (29) hose (12) and tee
(13) from intake manifold. Discard hoses
(12, 15, 16, 17), filter (14) and reducer (29).
f.
Remove ignition harness assembly from
engine and discard.
4. Remove nuts (5), lock washers (4), and magneto
holding washers (3) from each magneto.
Discard lock washers (4).
Separate clamps (18), hoses (12, 15), Filter
(13) and tee (13). Discard hoses (12, 15),
Filter (13) and tee (13).
5. Remove both magnetos (2) from the engine.
2. Remove ignition harness assembly:
NOMENCLATURE FOR FIGURE 6-2.
1.
2.
3.
4.
5.
6.
7.
8.
6-4
Magneto
Gasket
Washer, Holding
Washer, Lock
Nut
Bushing
Retainer
Gear
9.
10.
11.
12.
13.
14.
15.
16.
Washer, Thrust
Bearing, Needle
Sleeve
Hose
Tee
Filter
Hose
Hose
17.
18.
19.
20.
21.
22.
23.
24.
Hose
Clamp
Elbow
Bushing
Harness
Sparkplug
Screw
Clamp
25.
26.
27.
28.
29.
Clamp
Tie, Cable
Screw
Nut, Self Locking
Reducer
Chapter 6
FIGURE 6-2 IGNITION SYSTEM
6-5
Chapter 6
6-3 FUEL INJECTION
SYSTEM REMOVAL AND
DISASSEMBLY (See Figure 6-3.)
1. Mark each fuel injection line (49) through (54)
with its cylinder number to facilitate
re-installation.
WARNING
Fuel injection lines must not be bent or
deformed. Discard and replace bent or
deformed fuel injection lines.
1. Fuel injection line removal:
a. Remove self-locking nuts (68), flat washers
(67), cushioned loop clamps (66), and bolts
(69). Cushioned loop clamp (65) will be
removed later. Discard self locking nuts
(68).
b. Disconnect fuel lines (49 through 54) from
fuel injection sleeves (70).
c. Disconnect other end of fuel lines from fuel
manifold valve assembly (48) and remove
fuel lines from engine.
d. Remove washers (55, 56).
3. Remove the 2-4-6 side air reference tube
assembly (39) and air manifold tube assembly
(41). Loosen and remove sleeves (70) from air
manifold tube assembly (41).
4. Remove the 1-3-5 side air reference tube
assembly (40) and air manifold tube assembly
(41). Loosen and remove sleeves (70) from air
manifold tube assembly (41).
6-6
5. Fuel Nozzle Removal:
a. Remove fuel nozzles (58) from each
cylinder.
b. Remove o-rings (57) from nozzles (58) and
discard.
6. Remove fuel hose (42), fitting (43), and hose
(44) from fuel servo and fuel pump. Discard
fuel hoses (42, 44).
7. Cut and remove tie strap (71). Loosen clamps
(36) and remove air reference hose (37) from air
throttle adapter and fuel pump. Discard hose
(37) and tie strap (71).
8. Remove hose (46) from fuel servo and fuel
manifold valve. Remove hoses (73, 72) from
controller assembly (2). Discard hoses (46, 72,
73).
9. Remove the crankcase backbone hardware that
secures the fuel manifold valve to the engine
and remove fuel manifold valve (48).
10. See Figure 6-4, "Induction System." Remove
clamp (23) and hose (21) between air throttle
adapter and induction tube (22). Remove the
assembled tubes, aftercooler, bracket and place
on a work bench to be separated later. Discard
hose (21). See Figure 6-3, "Fuel System."
Remove screws (23), lock washers (22) and
washers (21). Remove air throttle adapter
assembly (28), fuel servo(1), controller (2) and
overboost valve (32) as an assembly from the
engine. Discard gaskets (20, 24) and lock
washers (22, 26).
11. Remove nuts (61), lock washers (60) and
washers (59). Remove fuel pump assembly (64)
and gasket (62). Reach into crankcase fuel pump
cavity and remove drive shaft (63). Discard fuel
pump gasket (62) and lock washers (60).
Chapter 6
FIGURE 6-3. FUEL INJECTION SYSTEM
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Servo, Fuel
Controller
Lever
Bushing
Pin
Washer, Wave
Washer
Pin, Cotter
Nut, Self Locking
Spring
Rod End
Rod and Link Assembly
Screw
Washer, Lock
Washer, Plain
Gasket
Manifold
Plug
Elbow
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Gasket
Washer, Plain
Washer, Lock
Screw
Gasket
Washer, Plain
Washer, Lock
Screw
Adapter
Connector
Fitting
Fitting
Valve, Overboost
O-Ring
Screw
Washer, Lock
Clamp
Hose
Hose
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
Tube, Air Reference
Tube, Air Reference
Tube, Air Manifold
Hose
Nipple
Hose
Elbow
Hose
Elbow
Fuel Manifold Valve
Tube, Fuel #1 Cyl.
Tube, Fuel #2 Cyl.
Tube, Fuel #3 Cyl.
Tube, Fuel #4 Cyl.
Tube, Fuel #5 Cyl.
Tube, Fuel #6 Cyl.
Washer
Washer
O-Ring
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
Fuel Nozzle
Washer, Plain
Washer, Lock
Nut
Gasket
Shaft, Fuel Pump Drive
Fuel Pump
Clamp
Clamp
Washer,, Flat
Nut, Self Locking
Bolt
Sleeve
Strap, Tie
Hose
Hose
6-7
Chapter 6
6-4 INDUCTION SYSTEM
REMOVAL AND DISASSEMBLY
(See Figure 6-4.)
1. The aftercooler and attached tubes, air throttle
adapter, fuel servo, overboost valve and controller
assembly were removed during fuel system
disassembly.
intake manifold (2) and induction tubes (6
through 13) as an assembly from the engine.
Discard lock washers (17).
3. Loosen clamps (19) and separate induction tubes
(6 through 13) from intake manifold (2). Remove
and discard hoses (20).
4. Remove gaskets (15) from cylinders and discard.
2. Remove nuts (18), lock washers (17) and plain
washers (16) from each cylinder. Remove the
NOMENCLATURE FOR FIGURE 6-4.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
6-8
Gasket,
Manifold
Washer, Plain
Washer, Lock
Screw
Tube, Ind., Cyl. #1
Tube, Ind., Cyl. #2
Tube, Ind., Cyl. #3
Tube, Ind., Cyl. #4
Tube, Ind., Cyl. #5
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Tube, Ind., Cyl. #5
Tube, Ind. Cyl. #6
Tube, Ind., Cyl. #6
Flange, Ind. Tube
Gasket
Washer, Plain
Washer, Lock
Nut, Plain
Clamp
Hose
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Hose
Tube, Ind., Aftercooler
Clamp, Assembly
Hose
Clamp, Assembly
Aftercooler
Bracket, Aftercooler
Mount, Vibration Damper
Washer, Lock
Nut, Plain
31.
32.
33.
34.
35.
Sealant, Adhesive
Hose
Bumper, Rubber
Adhesive
Elbow
Chapter 6
FIGURE 6-4. INDUCTION SYSTEM
6-9
Chapter 6
6-5 COMPRESSOR MOUNTING
COMPONENTS, STARTER AND
STARTER DRIVE ADAPTER
REMOVAL TSI0-360-RB (See
Figure 6-5.)
1. Remove airframe supplied freon compressor and
compressor drive belt in accordance with the
airframe manufacturer's instructions.
2. Remove attaching parts (30,31) and pull starter
(29) from adapter studs. Remove and discard
O-Ring (28).
3. Remove attaching parts (68 through 74). Remove
bracket (63) and lifting eye (64). Pull starter and
accessory drive adapter from crankcase.
4. Remove and discard silk thread (1).
NOMENCLATURE FOR FIGURE 6-5.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
6-10
Thread, Silk
Housing, Adapter
Stud
Stud
Stud
Dowel
Bearing, Needle
Shaft, Str. Worm
Bearing, Ball
Ring, Retaining
Ring, Retaining
Bearing, Needle
Gear, Worm Wheel
Spring, Clutch
Washer, Tab
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Screw
Shaft Gear
O-Ring
Gear, Scavenge
Bushing
Gear Scav.
Cover Scav.
Bearing, Needle
Washer
Screw
Lockwire
Key, Woodruff
0-Ring
Motor, Starter
Washer
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
Nut
Bushing
Adapter, Hsg.
Plug
Seal, Oil
Seal, Oil
Bushing
Bushing
Dowel
Stud
Stud
Elbow
Elbow
Shaft Gear
Key, Square
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
Gear, Bevel
Ring, Retaining
Gear, Bevel
Gear, Bevel
Gasket, Cover
Cover, Acc.
Washer, Plain
Washer, Lock
Nut, Plain
Bearing
Seal, Oil
Housing
Sheave
Washer, Sheave
Bolt
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
Thread, Silk
Bracket
Bracket
Eye, Lifling,
Washer
Nut
Nut
Washer, Plain
Washer, Lock
Bolt
Bolt
Nut
Bolt
Bolt
Chapter 6
FIGURE 6-5. COMPRESSOR MOUNTING COMPONENTS, STARTER AND STARTER
ADAPTER ASSEMBLY (TSIO-360-RB)
6-11
Chapter 6
2. Remove alternator adjusting bolt (11), washer
(10) and lock washer (9). Discard lock washer (9).
6-6 BELT DRIVEN
ALTERNATOR REMOVAL (See
Figure 6-6)
1. The alternator drive belt was removed during
engine removal in section 6-2.
3. Remove alternator mounting bolt (4), washers (5),
shims (6) and nut (7). Remove alternator
assembly (1) from mounting bracket (3).
4. Alternator brackets (3) and (8) will be removed
from the engine during crankcase disassembly.
NOMENCLATURE FOR FIGURE 6-6.
1.
2.
3.
4.
5.
6-12
Alternator
Belt, Alternator Drive
Bracket, Alternator Mount
Bolt
Washer
6.
7.
8.
9.
10.
Shim
Nut
Bracket, Adjusting
Washer, Lock
Washer
11.
12.
13.
14.
Bolt
Washer
Nut
Bolt
Chapter 6
FIGURE 6-6. BELT DRIVEN ALTERNATOR ASSEMBLY
6-13
Chapter 6
INTENTIONALLY
LEFT
BLANK
6-14
Chapter 6
6-7 ACCESSORY CASE
MOUNTED ALTERNATOR
REMOVAL (See Figure 6-7.)
1. Remove three sets of attaching parts (2, 3).
Remove alternator (4) from crankcase. Remove
and discard gasket (1).
2. Remove cotter pin (7) and nut (6). Remove gear
hub assembly from alternator shaft. Remove and
discard woodruff key (8).
3. Using a blind oil seal puller remove and discard
oil seal (9).
4. Remove and discard o-ring (10).
NOMENCLATURE FOR FIGURE 6-7.
Gasket
Washer, Plain
Nut
Alternator
Hub, Assembly
Nut
Pin, Cotter
Key, Woodruff
Oil Seal
O-Ring
FIGURE 6-7. ACCESSORY CASE MOUNTED ALTERNATOR ASSEMBLY
6-15
Chapter 6
6-8 OPTIONAL STARTER AND
STARTER DRIVE ADAPTER
TSI0-360-RB (See Figure 6-8)
2. Remove attaching parts (35 through 37, 47
through 52). Pull starter adapter from crankcase.
1. Remove attaching parts (45, 46) and pull starter
(44) from adapter studs. Remove and discard
o-ring (43).
NOMENCLATURE FOR FIGURE 6-8.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Gasket
Housing, Adapter
Stud
Stud
Stud
Dowel
Bearing, Needle
Shaft, Starter Worm
Bearing, Ball
Ring, Retaining
Ring, Retaining
Bearing, Needle
Gear, Worm Wheel
6-16
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Spring, Clutch
Washer, Tab
Screw
Shaft Gear, Starter
0-Ring
Body, Scav. Pump
Bushing
Seal, Oil
Stud
Elbow
Elbow
Gear, Scavenge
Bushing, Gear
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Gear, Scavenge
Key, Woodruff
Cover, Scav. Pump
Bushing
Pin, Dowel
Washer
Screw
Lockwire
Washer, Plain
Washer, Lock
Nut
Gasket, Cover
Cover, Acc. Dr.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
Washer, Plain
Washer, Lock
Nut, Plain
0-Ring
Motor, Starter
Washer
Nut
Bolt
Bolt
Bolt
Bolt
Eye, Engine Lifting
Spacer
Chapter 6
FIGURE 6-8. OPTIONAL STARTER ADAPTER ASSEMBLY (TSIO-360-RB)
6-17
Chapter 6
6-9 STARTER AND STARTER
DRIVE ADAPTER LTSI0-360-RB
(See Figure 6-9)
2. Remove attaching parts (37 through 39, 49
through 56). Pull starter adapter from crankcase.
1. Remove attaching parts (47, 48) and pull starter
(46) from adapter studs. Remove and discard
o-ring (45).
NOMENCLATURE FOR FIGURE 6-9.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Gasket
Housing, Adapter
Stud
Stud
Stud
Dowel
Bearing, Needle
Shaft, Starter Worm
Bearing, Ball
Gear, Starter Worm
Bushing
Pin
Bearing, Ball
Ring, Retaining
6-18
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Bearing, Needle
Gear, Worm Wheel
Spring, Clutch
Washer, Tab
Screw
Shaft Gear, Starter
0-Ring
Body, Scav. Pump
Bushing
Seal, Oil
Stud
Elbow
Gear, Scavenge
Bushing, Gear
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Gear, Scavenge
Key, Woodruff
Cover, Scav. Pump
Bushing
Pin, Dowel
Washer
Screw
Lockwire
Washer, Plain
Washer, Lock
Nut
Gasket, Cover
Cover, Acc. Dr.
Washer, Plain
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
Washer, Lock
Nut, Plain
0-Ring
Motor, Starter
Washer
Nut
Bolt
Washer, Plain
Washer, Lock
Bolt
Bolt
Bolt
Eye, Engine Lifting
Spacer
Chapter 6
FIGURE 6-9. STARTER ADAPTER ASSEMBLY (LTSI0-360-RB)
6-19
Chapter 6
6-10 ACCESSORY CASE
REMOVAL (See Figures 6-10 and
6-10A.)
1. Remove bolt (36), washers (32), lock washer (33)
and nut (34). Remove seven sets of washers (32),
6-20
2. lock washers (33) and nuts (34). Discard lock
washers (33). Remove four sets of washers (32),
lock washers (33) and bolts (35). Discard lock
washers (33).
3. Gently bump accessory case (2) with a soft rubber
or rawhide mallet and separate from crankcase.
Remove
and
discard
gasket
(1).
Chapter 6
FIGURE 6-10. ACCESSORY CASE (TSIO-360-RB)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Gasket
Accessory Case
Tube, Oil Filler
Gasket
Plug
Lockwire
Fitting
Plunger
Spring
Gasket
Cap
Screw, Adjusting
Washer
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Nut
Nut
Gasket
Cover
Washer
Washer, Lock
Nut
Gasket
Screen
Gasket
0-Ring
Adapter
Stud
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Fitting
Filter, Oil
Washer
Washer, Lock
Nut
Washer
Washer, Lock
Nut
Screw
Bolt
Gasket
Cap
Hose
6-21
Chapter 6
FIGURE 6-10A. ACCESSORY CASE (LTSIO-360-RB)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
6-22
Gasket
Accessory Case
Tube, Oil Filler
Gasket
Plug
Lockwire
Fitting
Plunger
Spring
Gasket
Cap
Screw, Adjusting
Washer
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Nut
Nut
Gasket
Cover
Washer
Washer, Lock
Nut
Gasket
Screen
Gasket
0-Ring
Adapter
Stud
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Fitting
Filter, Oil
Washer
Washer, Lock
Nut
Washer
Washer, Lock
Nut
Screw
Bolt
Gasket
Cap
Hose
Chapter 6
6-11 OIL PUMP REMOVAL (See
Figure 6-11)
See Chapter 14 for oil pump removal.
NOMENCLATURE FOR FIGURE 6-11.
1.
2.
3.
4.
5.
6.
7.
8.
Bushing
Gear, Oil Pump
Bushing
Gear Assembly, Oil Pump
Cover, Oil Pump
Washer, Tab
Bolt
Gear, Oil Pump Drive
FIGURE 6-11. OIL PUMP ASSEMBLY
6-23
Chapter 6
6-12 OIL COOLER REMOVAL
(See Figure 6-12.)
1. The oil cooler is located on the left (2-4-6) side,
rear portion of the crankcase.
2. Loosen and remove shoe (8), screw (10), nut (9)
from the number two cylinder rocker cover.
Loosen and remove screws (5), lock washers (4)
and washers (3). Remove oil cooler (2) and gasket
(1) from oil cooler adapter. Discard gasket
(1) and lock washers (4).
NOMENCLATURE FOR FIGURE 6-12.
1.
2.
3.
4.
Gasket
Oil Cooler
Washer, Plain
Washer, Lock
5.
6.
7.
8.
Screw
Gasket
Vernatherm (Oil Temp. Control Vlv.)
Shoe
FIGURE 6-12. OIL COOLER
6-24
9.
10.
11.
12.
Nut
Screw
Gasket
Plug
Chapter 6
6-13 OIL SUMP REMOVAL (See
Figure 6-13)
2. Gently bump oil sump (2) with a soft rubber or
rawhide mallet and separate from crankcase.
Remove and discard gasket (1).
1. Remove fourteen sets of nuts (6), lock washers (5)
and washers (4).
3. Remove oil suction tube (9) from oil sump (2).
NOMENCLATURE FOR FIGURE 6-13.
Gasket, Oil Sump
Sump, Oil
Helical Coil
Washer
Washer, Lock
Nut
Plug
Gasket, Plug
Tube, Oil Suction
FIGURE 6-13. OIL SUMP
6-25
Chapter 6
6-14 CYLINDER BAFFLING
DISASSEMBLY (See Figure 6-14)
1. On 1-3-5 side of engine, remove bolts (5) and
spacers (1). On 2-4-6 side of engine, remove bolts
(5) and spacers (1).
2. Remove screws (3), washers (14), and remove
supports (4).
3. Push fasteners (8) upward against springs (9) to
disengage fasteners from supports (2). Remove
fasteners and springs (8, 9). Remove supports (2)
from cylinder fins. Remove baffle assemblies (6,
7) and (10 through 14) from cylinders. Discard
springs (9).
NOMENCLATURE FOR FIGURE 6-14.
1.
2.
3.
4.
5.
6.
7.
6-26
Spacer
Support, Baffle, Outer
Screw
Support, Baffle, Inner
Bolt
Baffle
Baffle
8.
9.
10.
11.
12.
13.
14.
Baffle, Fastener
Spring
Baffle
Baffle
Baffle
Baffle
Washer, Plain
Chapter 6
FIGURE 6-14. CYLINDER BAFFLE ASSEMBLY
6-27
Chapter 6
6-15 CYLINDER AND PISTON
REMOVAL (See Figure 6-15)
1. Loosen and remove cylinder drain tubes (42).
Remove and discard drain tube seals (43).
Remove drain tube fittings (18).
2. Remove attaching hardware (30,31,32, 33) and
remove rocker covers (28, 29) from all cylinders.
Remove and discard gaskets (27).
3. Position the crankshaft so the piston is at top dead
center and both intake and exhaust valves of
cylinder to be removed are closed. Bend tab of
washers (25) down and remove nuts (26), tab
washers (25) and retainers (24). Remove rocker
arms (19) and shafts (23) from cylinder studs.
Discard tab washers (25), nuts (26), rocker shafts
(23) and retainers (24). Withdraw pushrods (41)
from housings.
4. Place the engine in the inverted position by
rotating the engine stand. Remove all pushrod
housings (36) by pushing in toward the crankcase
while lifting the cylinder end. Remove springs
5.
6.
7.
8.
(38), washers (39) and seal (37). Discard all seals
(37, 40) and springs (38).
Place the engine in the upright position by
rotating the engine stand. Make sure piston in
cylinder being removed is at the top dead center
position. Remove cylinder flange nuts (46, 47).
Cradle cylinder in arm and withdraw cylinder
straight out. To prevent damage to the crankcase
support the piston with your free hand as it clears
the cylinder.
Place cylinders upright on a workbench as they
are removed.
Remove piston pin (50) and piston (55) from
connecting rod. Remove the cylinder base
packing (1) from the cylinder skirt and install it in
a figure "8" pattern around the cylinder deck studs
and connecting rod for support. See Figure 615A, "Connecting Rod Support." Remove all
cylinders and pistons using steps "1" through "6".
Discard all piston pins (50), pistons (55), piston
rings (49, 51, 52, 53).
Using a retrieval magnet, remove all hydraulic
tappets (48) from the crankcase tappet bores.
Discard hydraulic tappets (48).
NOMENCLATURE FOR FIGURE 6-15.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
6-28
Packing
Cylinder
Helical Coil
Guide, Intake
Seal, Int. Vlv. Guide
Guide, Exhaust
Stud
Stud
Insert, ExhaustSeat
Insert, Intake Seat
VaIve, Exhaust
Valve, intake
Spring, Inner
Spring, Outer
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Retainer
Roto-Coil
Key, Valve Retainer
Fitting
Rocker Arm
Bushing
Screw,Drive #2
Washer, Thrust
Shaft
Retainer
Washer, Tab
Nut
Gasket
Cover, Rocker
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Cover, Rocker
Washer, Plain
Washer, Lock
Screw
Screw
Gasket
Nut Brass
Housing, Pushrod
Seal
Spring
Washer
Seal
Pushrod
Tube, Drain
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
Sleeve
Baffle
Spring
Nut, Flanged
Nut, Flanged
Tappet, Hydraulic
Ring, Compression
Ring, Compression
Ring, Oil Control
Ring, Scraper
Pin Piston
Piston
Chapter 6
FIGURE 6-15. CYLINDER AND PISTON ASSEMBLY
FIGURE 6-15A. CONNECTING ROD SUPPORT
6-29
Chapter 6
6-16 CRANKCASE
ASSOCIATED PARTS
REMOVAL (See Figure 6-16)
1. Remove screws (6) and remove oil seal retainer
plates (5).
2. Remove screws (4), lock washers (3), camshaft
cover (2) and gasket (1). Discard lock washers (3)
and gasket (1).
3. Remove screw (14), washer (12) and self locking
nut (13). Discard self locking nut (13). If oil
gauge (17) is still installed in housing , remove it.
Loosen clamps (7) and separate oil gauge housing
(9) and hose (8) from oil housing adapter. Discard
hose (8). Remove o-ring (16) and lock ring(10)
from oil gauge rod and discard. Remove clamp
(11) from oil gauge housing (9) and remove
clamp
(15)
from
oil
filler
neck.
4.
NOMENCLATURE FOR FIGURE 6-16.
Gasket
Cover, Camshaft
Washer, Lock
Screw, Camshaft Cover
Plate, Oil Seal Retainer
Screw, Retainer
6-30
Clamp, Hose
Hose
Housing, Oil Gauge
Lock Ring, Oil gauge
Clamp
Washer
Nut, Self Locking
Screw
Clamp
0-Ring
0il Gauge
Chapter 6
FIGURE 6-16. CRANKCASE ASSOCIATED PARTS
6-31
Chapter 6
discard all o-rings (23, 24 and 29) from engine
mount oil cooler adapter and 2-4-6 side
crankcase.
6-17 CRANKCASE
DISASSEMBLY AND DRIVE
TRAIN REMOVAL (See Figure 617.)
6. Lift off 2-4-6 crankcase half being careful to
prevent connecting rods from hitting cylinder
decks. Place the 2-4-6 side crankcase half on a
work bench. For determination of wear before
removing drive train, use the proper fixture and
dial indicators to check gear backlash and record.
See Figure 19-5, "Gear Backlash Fits and Limits."
7. See Figures 6-18 and 6-19. Lift out camshaft and
governor drive gear. Remove crankshaft
assembly. Place the camshaft and crankshaft
assemblies on the proper holding fixtures to
prevent damage. Remove and discard crankshaft
bearings and thrust washers.
1. Remove crankcase backbone attaching hardware
(1 through 6), remove lifting eye (25), shock
mount braces (8), shock mount (9), washer (10),
lock washer (11), nut (12) and fuel manifold
valve (26). Discard lock washer (11) and rubber
shock mount (9).
2. Rotate engine stand to place right crankcase half
downward.
3. Remove remaining attaching hardware (4, 5 and
28, 30). Remove attaching hardware (20, 21, 22).
Tap 7/16 through bolts (31 through 34) with a
non marring hammer. Remove and discard
through bolts (31 through 34) and o-rings (29).
8. See Figure 6-17. Disconnect 1-3-5 side crankcase
engine mounts from engine stand. Remove 1-3-5
side crankcase from engine stand and place on a
work bench. Remove engine mount bracket (35),
turbocharger support bracket (48), engine mount
bracket (37), alternator support bracket (39) and
spacers (40). Remove and discard all o-rings (23,
24) from 1-3-5 side crankcase.
9. Disassembly of drive train components will be
accomplished
in
Chapter
18.
4. Remove and discard through bolts (13, 14, 15, 18
and 19).
5. Disconnect 2-4-6 side crankcase engine mounts
from engine stand. Remove engine mount bracket
(38), prop cable bracket (17), bushing (16) and
engine mount oil cooler adapter (36). Remove and
NOMENCLATURE FOR FIGURE 6-17.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Bolt
Bolt
Bolt
Washer, Plain
Nut, Plain
Washer, Plain
Bolt, Through
Brace, Shock Mount
Mount, Shock
Washer
Washer, Lock
Nut
Bolt, Through
Bolt Through
6-32
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Bolt, Through
Bushing
Bracket, Prop Cable
Bolt, Through
Bolt, Through
Washer, Plain
Washer, Plain
Nut, Plain
O-Ring
O-Ring
Eye, Engine Lifting
Manifold, Valve
Bolt, Through
Nut
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
O-Ring
Washer, Plain
Bolt, Through
Bolt, Through
Bolt, Through
Bolt, Through
Bracket, Engine Mount
Bracket, Engine Mount
Bracket, Engine Mount
Bracket, Engine Mount
Bracket, Alternator Mount
Spacer, Bracket
Bushing, Magneto Support
Nut, Spiral Lock
43.
44.
45.
46.
47.
48.
49.
50.
Cover, Governor
Gasket, Cover, Governor
Spacer
Washer, Plain
Washer, Lock
Bracket, Turbo, Inner
Gasket, Copper
Plug
Chapter 6
FIGURE 6-17. CRANKCASE ATTACHING PARTS
6-33
Chapter 6
FIGURE 6-18. CAMSHAFT ASSEMBLY.
Camshaft Assembly
Gear, Camshaft
Bolt
6-34
Key, Woodruff
Gear, Governor Drive
Gear, Governor Driven
Fuel Pump Drive Shaft
Tappet, Hydraulic
Chapter 6
FIGURE 6-19. CRANKSHAFT ASSEMBLY
1.
2.
3.
4.
5.
6.
Plug, Crankshaft
Bushing, Crankshaft
Counterweight Assembly
Bushing, Counterweight
Pin, 4-1/2 Order
Pin, 6th Order
7.
8.
9.
10.
11.
12.
Plate, Retaining
Ring, Retaining
Pin, Dowel
Bearing, Crankshaft
Beanng, Crankshaft
Packing
13.
14.
15.
16.
17.
18.
Washer, Thrust
Gear, Crankshaft
Screw, Crankshaft Gear
Seal, Oil
Spring
Connecting Rod
19.
20.
21.
22.
23.
24.
Bushing
Bolt, Connecting Rod
Nut
Bearing, Conn. Rod
Cotter Pin
Crankshaft
6-35
Chapter 6
INTENTIONALLY
LEFT
BLANK
6-36
Chapter 7
CHAPTER 7
EXHAUST SYSTEM
SECTION
7-1
7-2
7-3
7-4
7-5
7-6
7-7
PAGE
Exhaust System Removal And Disassembly..................7-2
Turbocharger Disassembly..............................................7-4
Wastegate Disassembly...................................................7-4
Cleaning...........................................................................7-4
Inspection.........................................................................7-4
Exhaust System Repair And Replacement .....................7-5
Exhaust System Component Sub-assembly ...................7-5
FIGURE
7-1
7-2
PAGE
Exhaust System ..............................................................7-3
Slipjoint Assembly ..........................................................7-4
7-1
Chapter 7
7-1 TURBOCHARGER
REMOVAL
1. See Figure 6-1. Bend tabs of tab washers (76)
away from bolt (44) head flats. Remove three
bolts (44) and separate bracket (47) from
turbocharger (21). Discard tab washers (76).
2. Remove two bolts (32), lockwashers (31), oil
outlet adapter (30) and gasket (29). Discard
gasket (29) and lockwashers (31).
3. Remove two bolts (36), lockwashers (35), oil inlet
adapter (34) and gasket (33). Discard gasket (33)
and lockwashers (31).
4. Separate adapters (30, 34) and fittings (51, 56).
5. The turbocharger must be cleaned, inspected and
repaired or replaced in accordance with the
component manufacturer's instructions at engine
overhaul. See section 1-5, "Related Publications."
7-2 WASTEGATE REMOVAL
1. See Figure 6-1. Remove fittings (63, 67) and
o-rings (62, 66) from wastegate (38). Discard
o-rings (62, 66).
2. The wastegate must be cleaned, inspected and
repaired or replaced in accordance with the
component manufacturer's instructions at engine
overhaul. See section 1-5, "Related Publications."
7-3 CLEANING
1. In order to thoroughly inspect the exhaust system,
components must be clean and free of carbon, oil,
grease, and any other material. Use a suitable
solvent (such as Stoddard solvent), apply by
spraying, allow solvent to drain and wipe dry with
a clean cloth.
CAUTION…
Never use flammable solvents, wire brushes or
abrasive to clean exhaust systems and never use a
lead pencil to mark any exhaust system component.
7-4 INSPECTION
Inspection of the complete exhaust system must be
accomplished at overhaul. The entire exhaust must be
cleaned and visually inspected for condition and leaks
using the following procedure.
1. Visual Inspection - Stacks, Risers, Elbows Inspect these components for burned areas,
corrosion, erosion, cracks and looseness using a
10X magnifying glass. Exhaust system
components exhibiting erosion, corrosion or that
are less than the required thickness must be
replaced with new. During this inspection
examine the condition of welded areas and seams
for cracks. Any exhaust system component that is
cracked must be discarded. Visually inspect
slipjoints for bulging and cracks. See Figure 7-1.
"Slipjoints."
FIGURE 7-1 SLIPJOINT ASSEMBLY
7-2
Chapter 7
1. The "V" band clamps must be replaced at engine
overhaul. Discard "V" band clamps.
7-5 EXHAUST SYSTEM
REPAIR AND REPLACEMENT
1. Welding of exhaust system components is not
permissible. Any components found to be
malfunctioning must be replaced.
7-6 EXHAUST SYSTEM
COMPONENT SUB-ASSEMBLY
1. Using new gasket (33), install oil inlet adapter
(34) on turbocharger (21) and secure with two
bolts (36) and new lockwashers (35). Torque
bolts (36) to 155-175 inch pounds.
2. Using new gasket (29), install oil outlet adapter
(30) on turbocharger (21) and secure with two
bolts (32) and new lockwashers (31). Torque
bolts (36) to 220-260 inch pounds.
3. Install bushing (52) and fittings (51, 56).
4. Using new o-rings (62, 66), install fittings (63,
67) in wastegate assembly (38).
5. Store all exhaust system components in a clean
protected area until final engine assembly.
7-3
Chapter 7
INTENTIONALLY
LEFT
BLANK
7-4
Chapter 8
CHAPTER 8
IGNITION SYSTEM
SECTION
8-1
8-2
8-3
8-4
8-5
8-6
8-7
8-8
PAGE
Magneto Drive Gear Disassembly ............................................. 8-2
Magneto Overhaul ...................................................................... 8-2
Magneto Drive Gear Cleaning.................................................... 8-2
Magneto Drive Gear Inspection ................................................. 8-2
Magneto Drive Gear Disassembly.............................................. 8-4
Magnetic Particle Inspection ...................................................... 8-4
Magneto Drive Gear Assembly .................................................. 8-4
Ignition System sub-assembly ................................................... 8-5
FIGURE
8-1
8-2
8-3
PAGE
Gear Tooth Profile ...................................................................... 8-3
Magneto Drive Gear Assembly .................................................. 8-4
Needle Bearing Installation ........................................................ 8-5
8-1
Chapter 8
8-1 MAGNETO DRIVE GEAR
DISASSEMBLY (See Figure 8-1.)
1. Remove both magneto drive gear assemblies:
2. Reach into the accessory case magneto openings
and carefully slide each magneto drive gear
assembly out.
3. Separate rubber drive bushings (6), retainers (7)
and drive gears (8). Discard rubber drive bushings
(6).
8-2 MAGNETO OVERHAUL
1. Discard all ignition system parts listed in Section
5-6, "100% Replacement Parts."
2. Magneto assemblies must be overhauled in
accordance with the magneto manufacturer's
instructions. For TCM magnetos, see TCM
Ignition Systems Master Service Manual, Form
No. X40000. For Slick ignition components, see
Slick Ignition Systems Master Service Manual,
Index and Order Form Number F-1100. See
Section 1-5, "Related Publications," for ordering
information.
8-3 MAGNETO DRIVE GEAR
CLEANING
Clean the magneto drive gear assemblies using
mineral spirits solvent or by immersion in an alkaline
8-2
stripping bath if mineral spirit solvent is not effective.
After cleaning with alkaline solution, the gears must
be sprayed with steam to remove all traces of alkaline.
After steam rinsing, the gears must be thoroughly
flushed with mineral spirits solvent. Insure that the
magneto drive gear lubrication holes are clear and
unobstructed.
CAUTION...
Alkaline cleaning solutions will cause corrosion on
metals if not completely removed.
WARNING
Do not pressure blast gears with an abrasive
media. Blasting will remove surface
hardening.
8-4 MAGNETO DRIVE GEAR
INSPECTION
Inspect the magneto drive gear teeth for signs of
overheating and excessive wear. Normal wear
produces a fine polish on the tooth thrust faces. Gears
that have alteration of the tooth profiles, score marks,
burning, pitting, nicks, burrs or corrosion must be
discarded. See Figure 8-1, “Gear Tooth Inspection,”
for acceptable and unacceptable gear tooth wear.
FIGURE 8-1. GEAR TOOTH INSPECTION
8-3
Chapter 8
FIGURE 8-2. MAGNETO DRIVE GEAR ASSEMBLY
8-5 MAGNETO DRIVE GEAR
DISASSEMBLY
See Figure 8-3. Place each of the drive gear
assemblies (one at the time) on bearing/thrust washer
removal fixture with the sleeve end up. Center the
drive gear and removal fixture under the removal tool
and arbor press. Press the thrust washer and needle
bearing out of the drive gear. Do not remove sleeve
from the drive gear. Discard the removed thrust
washer and needle bearing. Inspect the drive gear
inside diameter. Drive gears with inside diameters
exceeding 1.1244 - 1.1255 must be discarded. Drive
gears with loose sleeves must be discarded. Drive gear
assemblies with any damage resulting during the
disassembly procedure must be discarded.
8-6 MAGNETIC PARTICLE
INSPECTION
Magneto drive gears and drive bushing retainers must
be inspected by a certified technician in accordance
8-4
with Section 5-9, "Magnetic Particle Inspection."
Magneto drive gears that exhibit cracks, must be
discarded.
8-7 MAGNETO DRIVE GEAR
ASSEMBLY
Clean the magneto drive gears in accordance with
Section 8-3. Using the proper size installation tool
install a new thrust washer in each of the the magneto
drive gear assemblies as specified in Figure 8-3. The
thrust washer must be seated against the sleeve.
See Figure 8-3, "Needle Bearing Installation." Using
an arbor press and an installation tool conforming
with the specifications in Figure 8-3, install a new
needle bearing into each of the magneto drive gear
assemblies to the location specified in Figure 8-2.
Clean the magneto drive gears in accordance with
Section 8-3. Drive gear assemblies with any damage
resulting during the assembly procedure must be
discarded.
Chapter 8
FIGURE 8-3. NEEDLE BEARING INSTALLATION
8-8 IGNITION SYSTEM
SUB-ASSEMBLY
1. Magneto assemblies must be sub-assembled in
accordance with the magneto manufacturer's
instructions. For TCM magnetos, see TCM
Ignition Systems Master Service Manual, Form
No. X40000. For Slick ignition components, see
Slick Ignition Systems Master Service Manual,
Index and Order Form Number F-1100. See
Section 1-5, "Related Publications," for ordering
information.
2. The magneto drive gear assemblies and magnetos
will be installed on the engine during final engine
assembly. Store all components in a clean
protected area until final engine assembly.
8-5
Chapter 8
INTENTIONALLY
LEFT
BLANK
8-6
Chapter 9
CHAPTER 9
FUEL INJECTION SYSTEM
SECTION
PAGE
9-1
Fuel Injection System Component Disassembly........................ 9-2
Fuel Manifold Valve................................................................... 9-2
Fuel Pump ................................................................................... 9-3
Air Throttle Adapter ................................................................... 9-4
Fuel Nozzles................................................................................ 9-6
9-2
Fuel Injection System Cleaning.................................................. 9-6
9-3
Fuel Injection System Inspection ............................................... 9-7
9-4
Fuel Injection System Repair And Replacement ....................... 9-9
9-5
Fuel Injection System Sub-assembly.......................................... 9-9
FIGURE
PAGE
9-1
Fuel Manifold Valve Fitting Orientation.................................... 9-2
9-2
Fuel Pump Fitting Locations ...................................................... 9-3
9-3
Air Throttle Adapter, Fuel Servo, Controller
And Overboost Valve ................................................................. 9-5
9-4
Fuel Nozzle ................................................................................. 9-6
9-5
Fuel Pump Drive Coupling Fits And Limits .............................. 9-8
9-6
General Lever Bushing Replacement......................................... 9-9
9-7
General F/I Sealant Application ................................................. 9-10
9-8
Link Rod Assembly .................................................................... 9-11
9-1
Chapter 9
9-1 FUEL INJECTION SYSTEM
COMPONENT DISASSEMBLY
FUEL MANIFOLD VALVE
1. See Figure 9-1, "Fuel Manifold Valve Fitting
Orientation." Remove fittings "A" through "C."
2. The fuel manifold valve must be overhauled in
accordance with TCM Fuel Injection Systems
Overhaul Manual and Parts Catalog, Form
X30593A.
See
Section
1-5,
"Related
Publications," for ordering information. Teledyne
Continental Motors offers factory rebuilt fuel
injection system components at exchange prices
as an alternative to field overhaul
of these units.
FIGURE 9-1. FUEL PUMP FITTING LOCATIONS
9-2
ENGINE
MODEL
Fitting
"A"
FUEL INLET
L/TSI0-360-RB
45° Elbow @ (135°)
Fitting
"B"
Metered Fuel
Press. Conn
Plug
Fitting
"C"
Manifold
Vent
90° Elbow @ (225°)
Chapter 9
FUEL PUMP
1. See Figure 9-2, "Fuel Pump Fitting Locations."
Remove fittings "A" through "D."
2. The fuel pump must be overhauled in accordance
with TCM Fuel Injection Systems Overhaul
Manual and Parts Catalog, Form X30593A. See
Section 1-5, "Related Publications," for ordering
information. Teledyne Continental Motors offers
factory rebuilt fuel injection system components at
exchange prices as an alternative to field overhaul
of these units.
FIGURE 9-2. FUEL PUMP FITTING LOCATIONS
ENGINE
MODEL
L/TSI0-360-RB
FITTING
"A"
Inlet
90° Elbow @ 180°
FITTING
"B"
Outlet
90° Elbow @ 180°
FITTING "C"
Seal
Drain
Straight Fitting
FITTING "D"
Air Reference
90° Elbow @ 90°
9-3
Chapter 9
AIR THROTTLE ADAPTER
1. See Figure 9-3, "Adapter, Fuel Servo, Controller
& Overboost Valve." Remove controller (7) from
air throttle adapter assembly (1):
a. Cut and remove lockwire.
b. Record rod end position on rod and link
assembly by counting exposed threads of nut
(16). Remove nut (16) from rod and link
assembly (13).
c. Remove cotter pin (12) and plain washer (10)
from rod end (15). Discard cotter pin (12).
d. Remove wave washer (11), rod end (15), and
spring (14) from rod and link assembly (13).
Discard wave washer (11) and spring (14).
e. Remove rod and link assembly (13) by
removing cotter pin (12), plain washer (10),
and wave washer (11). Discard cotter pin (12)
and wave washer (11).
f.
Remove swaged lever pin (28) from lever
(29) and remove lever from the controller (2).
Discard pin (28).
g. Remove four phillips head screws (6), four
lock washers (5), and four washers (4).
Discard lock washers (5).
h. Remove controller (2) from air throttle
adapter assembly (1).
9-4
I.
Discard controller gasket (3).
j.
The turbocharger controller assembly must be
overhauled in accordance with the Airesearch
Overhaul Manual for Aircraft System Valves
and Controllers. See Section 1-5, "Related
Publications," for ordering information.
2. See Figure 9-3, "Adapter, Fuel Servo, Controller
& Overboost Valve." Remove overboost valve
(22) from air throttle adapter assembly (1):
a. Cut and remove lockwire.
b. Remove four phillips head screws (26), four
plain washers (24), and four lock washers
(25). Discard lock washers (25).
c. Remove overboost valve assembly (22) from
air throttle adapter (1).
d. Discard "O"ring seal (23).
e. The overboost valve must be overhauled in
accordance with the Airesearch Overhaul
Manual for Aircraft System Valves and
Controllers. See Section 1-5, "Related
Publications," for ordering information.
3. See Figure 9-3, "Adapter, Fuel Servo, Controller
& Overboost Valve." Remove fuel servo
assembly (2) from air throttle adapter assembly
(1):
a. Remove cap screws (6), four plain washers
(4), and four lock washers (5). Discard lock
washers (5).
b. The fuel servo assembly must be overhauled
in accordance with Precision Fuel System
Manuals, Form 15-338, RSA5 Operator and
Service Manual and Form 15-900, RSA5AD2
Overhaul Instructions. See Section 1-5,
"Related
Publications,"
for
ordering
information.
4. See Figure 6-3, "Fuel Injection System." Remove
magneto pressure fittings (30, 31) and air
reference tube fittings (29) from air throttle
adapter (28).
Chapter 9
FIGURE 9-3. AIR THROTTLE ADAPTER, FUEL SERVO, CONTROLLER
AND OVERBOOST VALVE
9-5
Chapter 9
FUEL NOZZLES
NOTE…
1. The fuel nozzles must be overhauled in
accordance with TCM Fuel Injection Systems
Overhaul Manual and Parts Catalog, Form
X30593A.
See
Section
1-5,
"Related
Publications," for ordering information.
Further disassembly of the fuel injection system
components is not advised unless the proper flow
test equipment is available. Teledyne
Continental Motors offers factory rebuilt fuel
injection system components at exchange prices
as an alternative to field overhaul of these units.
FIGURE 9-4. FUEL NOZZLE
9-2 FUEL INJECTION SYSTEM
CLEANING
All fuel injection system components and associated
hardware must be cleaned in accordance with the
instructions in Section 5-7, "General Cleaning," and
the following special instructions:
1. All gaskets, packings, o-rings, seals, self locking
nuts, wave washers, cotter pins and lock washers
removed from the fuel injection system and
components must be replaced 100% at overhaul.
Cleaning these parts is not required.
2. The fuel pump, fuel manifold valve and fuel
nozzles must be cleaned, inspected, overhauled
and tested in accordance with the instructions in
TCM Fuel Injection Systems Overhaul and Parts
9-6
Catalog, Form X30593A, unless factory rebuilt
units are purchased for replacement.
3. The fuel servo assembly must be cleaned,
inspected, overhauled and tested in accordance
with Precision Fuel System instructions. See
Section 1-5, "Related Publications," for ordering
information.
9-3 FUEL INJECTION SYSTEM
INSPECTION
VISUAL INSPECTION
The visual inspection must be performed in
accordance with the instructions in Section 5-8,
"Visual Inspection". Special attention must be given
to the following components and areas:
1. Visually inspect all fuel injection system
plumbing for cracks, dents, chafing, flared ends
for cracks, out of roundness. Inspect fittings for
distorted or stripped threads and damaged wrench
flats. Components exhibiting any of the above
indications must be discarded.
FLUORESCENT PENETRANT INSPECTION
Fluorescent penetrant inspection must be performed
on applicable aluminum alloy fuel injection system
components by a certified technician in accordance
with the instructions in Section 5-12, "Fluorescent
Penetrant Inspection."
2. Inspect brackets as applicable for cracks, dents
and wear. Inspect hardware for distorted, stripped
threads and damaged wrench flats. Components
exhibiting any of the above indications must be
discarded.
During overhaul of fuel injection system components
in accordance with Form X30593A all aluminum
alloy parts such as fuel pump body, vapor separator,
manifold valve body, air throttle adapter body, covers
and flanges must be fluorescent penetrant inspected
by a certified technician in accordance with Section
5-12, "Fluorescent Penetrant Inspection," of this
manual. Any components exhibiting cracks must be
discarded.
3. Visually inspect the fuel pump, manifold valve
and fuel nozzle outside areas for evidence of
wear, deterioration and leakage. Inspect tapped
holes and helical coils for distorted or stripped
threads. Inspect for cracks and dents. Further
inspection of the fuel pump, manifold valve,
nozzles and fuel metering unit must be performed
in accordance with the instructions in TCM Fuel
Injection Systems Overhaul and Parts Catalog,
Form X30593A.
MAGNETIC PARTICLE INSPECTION
The fuel pump drive shaft must be magnetic particle
inspected by a certified technician in accordance with
the instructions in Section 5-9, "Magnetic Particle
Inspection." Any components exhibiting cracks must
be discarded.
9-7
Chapter 9
DIMENSIONAL INSPECTION
The following new parts limits must be used for dimensional inspection. Components that do not meet the
following specifications must be discarded.
All components must be thoroughly cleaned and air dried prior to dimensional inspection.
REF.
NO
1.
2.
3.
4.
5.
6.
7.
8.
DESCRIPTION
FUEL PUMP DRIVE
Fuel pump adapter pilot in crankcase................................................... diameter:
Fuel pump body pilot in adapter .......................................................... diameter:
Oil seal in adapter ................................................................................. diameter:
Fuel pump drive shaft in impeller shaft ............................................... diameter:
Fuel pump drive shaft in governor gear ............................................... clearance:
Governor driven gear in crankcase....................................................... diameter:
Governor driven gear bore in crankcase .............................................. diameter:
Governor drive gear to camshaft gear .................................................. backlash:
NEW PARTS
MIN. MAX.
0.001L
0.0005L
0.003T
0.002L
0.0015
0.0014L
0.875
0.002
FIGURE 9-5. FUEL PUMP DRIVE COUPLING FITS AND LIMITS
9-8
0.005L
0.0045L
0.009T
0.008L
0.0039
0.0034L
0.876
0.012
Chapter 9
9-4 FUEL INJECTION SYSTEM
REPAIR AND REPLACEMENT
Any fuel injection system component worn beyond
new parts limits or failing to meet the inspection
criteria in Section 9-3 must be replaced unless repair
is possible with the following instructions:
1. Any fuel system brackets, hardware, plumbing or
shafts found to have any of the discrepancies
listed in Section 9-3 must be replaced.
2. The turbocharger controller lever bushing must be
replaced during engine overhaul. Place the lever
bushing over a ring that will allow the bushing to
pass through. Using the correct size tool and an
arbor press, remove the old bushing. Inspect the
lever bushing bore for a diameter of .249 - .251.
Discard levers that exceed the specified
dimension. Using the correct size tool and an
arbor press, install the new bushing in accordance
with the specifications in Figure 9-7. The lever
and bushing must have a press fit of .007T to
.013T.
3. Replace all fuel injection system parts listed in
Section 5-6, "100% Replacement Parts."
4. Section 5-19, "Application Of Accelagold,"
applies to all aluminum alloy castings, sheet metal
and tubing.
9-5 FUEL INJECTION SYSTEM
SUB-ASSEMBLY
NOTE…
All fuel injection system components must be
overhauled or new, clean and free of debris before
assembly.
The fuel pump, fuel manifold valve and fuel nozzles
must be new, factory rebuilt or field overhauled and
tested in accordance with TCM Form X30593A Fuel
Injection Systems Overhaul and Parts Catalog.
NOTE…
Before reinstallation of fuel system component
fittings insure they are free of any debris by screwing
them into the proper size holes of a softwood block
then thoroughly flushing them with an approved
solvent.
WARNING
Never use Teflon tape on fuel injection
component fittings.
1. See Figure 9-1. Sparingly apply TCM 646940 F/I
sealant on fittings that have male tapered pipe
threads in accordance with Figure 9-7, "General
F/I Sealant Application." Install fittings “A”
through “C” into fuel manifold valve at the proper
locations and correct orientations.
2. See Figure 9-2. Sparingly apply TCM 646940 F/I
sealant on fittings that have male tapered pipe
threads in accordance with Figure 9-8, "General
F/I Sealant Application." Install fittings “A”
through “D” into fuel pump at the proper
locations and correct orientation.
3. See Figure 6-3. Sparingly apply TCM 646940 F/I
sealant on fittings that have male tapered pipe
threads in accordance with Figure 9-8, "General
F/I Sealant Application." Install fittings (29, 30
and 31) into air throttle adapter ((28).
FIGURE 9-6. GENERAL LEVER BUSHING REPLACEMENT
9-9
4. See Figure 9-3, "Air Throttle Adapter, Fuel
Servo, Controller And Overboost Valve." Install
fuel servo assembly (1):
5. Install new gasket (3) and fuel servo assembly (2)
on air throttle adapter (1) using four screws (6),
four new lock washers (5), and four plain washers
(4). The .88 inch long screws go in the lower
holes and the .75 inch long screws go in the upper
holes. Torque screws (6) to 75 - 85 inch pounds.
6. See Figure 9-3, "Air Throttle Adapter, Fuel
Servo, Controller And Overboost Valve." Install
new o-ring seal (23) and overboost valve (22) on
air throttle adapter assembly (1). Secure overboost
valve using four 10-24 screws (26), four new lock
washers (25), and four plain washers (24). Torque
screws (26) to 21 - 25 inch pounds. Safety wire
screws (26) in accordance with Section 4-2,
"Lockwire Procedure."
7. Install lever assembly on controller (29):
a. Install lever (29) on controller (2) shaft.
b. Install new lever pin (28) through lever (29)
and through controller shaft. Swage pin on
both ends using a swage fixture, pin punch
and ball peen hammer.
FIGURE 9-7. GENERAL F/I SEALANT APPLICATION
9-10
Chapter 9
8. See Figure 9-3, "Air Throttle Adapter, Fuel
Servo, Controller And Overboost Valve." Install
turbocharger controller (7):
a. Install new controller gasket (17) and
controller and lever assembly (7) on air
throttle adapter assembly (1) with four screws
(18), four new lock washers (19) and four
plain washers (20). Torque screws (18) to 21
- 25 inch pounds. Safety wire screws (18) in
accordance with Section 4-2, "Lockwire
Procedure."
9. See Figures 9-3 and 9-8. Install rod and link
assembly (13):
a. Assemble new spring (14) on rod and link
assembly (13) and insert end through rod end
(15). Install new self-locking nut (16) on
threaded end of (13). Adjust rod and link
assembly to original length as recorded.
b. Lubricate rod pin using Shell #5 or Lubriplate
#630AA or equivalent. Assemble one new
wave washer (11) on rod end (15).
c. Insert rod end (11) through lever (29) and
bushing (31). Attach rod end (15) using plain
washer (10) and new cotter pin (12).
d. Assemble one new wave washer (11) on free
end of rod & link assembly (13).
e. Insert free end of rod and link assembly (13)
into hole on throttle control arm of fuel servo
assembly.
f.
Install one plain washer (10) and one new
cotter pin (12).
g. Store all fuel injection components in a clean
protected area until final engine assembly.
FIGURE 9-8. LINK ROD ASSEMBLY
9-11
Chapter 9
INTENTIONALLY
LEFT
BLANK
9-12
Chapter 10
CHAPTER 10
INDUCTION SYSTEM
SECTION
10-1
10-2
10-3
10-4
10-5
PAGE
Aftercooler Disassembly .................................................10-3
Induction System Cleaning .............................................10-3
Induction System Inspection...........................................10-3
Induction System Component
Repair And Replacement ................................................10-3
Induction System Sub-assembly .....................................10-3
10-1
Chapter 10
INTENTIONALLY
LEFT
BLANK
10-2
Chapter 10
10-1 AFTERCOOLER
DISASSEMBLY
1. See Figure 6-4, “Induction System.” Loosen
clamps (25, 23) and remove hoses (21, 24, 32)
and tube (22) from aftercooler (26). Discard hoses
(21, 24, 32). Remove three nuts (30), three lock
washers (29) and separate bracket (27) from
aftercooler (26). Remove three vibration damper
mounts (28) from aftercooler assembly and
discard.
10-2 INDUCTION SYSTEM
CLEANING
All induction system components and associated
hardware must be cleaned in accordance with the
instructions in Section 5-7, "General Cleaning," and
the following special instructions:
threads. Inspect the aftercooler anchor nuts for
distorted or stripped threads.
4. Inspect the aftercooler mount bracket for cracks,
bending and corrosion. Discard aftercooler mount
brackets exhibiting any of these indications.
5. Inspect all induction system clamps for cracks,
corrosion and damaged screw threads. The screw
mechanism must operate without any binding.
Inspect the clamp for broken/loose rivets or spot
welds. Clamps exhibiting any of the above
conditions must be discarded.
FLUORESCENT PENETRANT INSPECTION
Fluorescent penetrant inspection must be performed
by a certified technician on all aluminum alloy
induction system components in accordance with the
instructions in Section 5-12, "Fluorescent Penetrant
Inspection."
All gaskets, hoses, lock washers and self locking nuts
removed from the induction system and components
must be replaced 100% at overhaul. Cleaning these
part is not required.
10-4 INDUCTION SYSTEM
COMPONENT REPAIR AND
REPLACEMENT
10-3 INDUCTION SYSTEM
INSPECTION
Any induction system component worn beyond new
parts limits or failing to meet the inspection criteria in
Section 10-3 must be replaced.
VISUAL INSPECTION
The visual inspection must be performed in
accordance with the instructions in Section 5-8,
"Visual Inspection" and the following:
1. Visually inspect induction tubes, risers and intake
manifold for cracks, dents and chafing. Check
tube ends and flanges on a surface plate for
warpage and out of roundness. Components
exhibiting cracks, dents, chafing, warpage or out
of roundness must be discarded.
2. Inspect all areas of the aftercooler especially
welded areas for cracks using a 10X magnifying
glass. Inspect the aftercooler for signs of leaks.
Inspect the aftercooler core for bent or cracked
fins.
3. Inspect tapped holes and helical coils in the intake
manifold and aftercooler for distorted or stripped
1. There are no structural repairs allowed to the
aftercooler
assembly.
Aftercoolers
with
structural damage, bent, broken or cracked
cooling fins must be replaced with a new or
serviceable aftercooler. Weld repairs to the
mounting flange brackets may be accomplished
by a certified repair facility.
2. Section 5-19, "Application Of Accelagold,"
applies to all aluminum alloy castings, sheet metal
and tubing.
10-5 INDUCTION SYSTEM
SUB-ASSEMBLY (See Figure 6-4.)
Apply a small amount of TCM P/N 646439 adhesive
on the aftercooler end of vibration damper mounts
(28) and install in aftercooler (26).
10-3
Chapter 10
INTENTIONALLY
LEFT
BLANK
10-4
Chapter 11
CHAPTER 11
AIR CONDITIONING
SECTION
11-1
11-2
11-3
11-4
11-5
FIGURE
11-1
11-2A
11-2B
11-2C
11-3
11-4
11-5
PAGE
Starter Motor, Starter Adapter And Accessory
Drive Adapter Disassembly .......................................... 11-2
Compressor Mounting Components,
Starter And Starter Adapter Cleaning ........................... 11-2
Compressor Brackets, Starter And Starter
Adapter Inspection ........................................................ 11-3
Compressor Mounting Component, Starter And
Starter Adapter Repair And Replacement..................... 11-8
Compressor Mounting Component, Starter And
Starter Adapter Sub-assembly TSI0-360-RB ............... 11-12
PAGE
Starter Adapter Stud Setting Heights............................ 11-4
Starter Adapter Fits & Limits ....................................... 11-6
Shaftgear Drum Dimensions......................................... 11-7
Worm Wheel Drum Dimensions .................................. 11-7
Starter Adapter Needle Bearing Installer...................... 11-9
Accessory Drive Adapter Cover Needle
Bearing Installation ....................................................... 11-11
Accessory Drive Housing Threading Procedure .......... 11-13
11-1
Chapter 11
11-1 STARTER MOTOR,
STARTER ADAPTER AND
ACCESSORY DRIVE ADAPTER
DISASSEMBLY
STARTER MOTOR
1. The starter motor assembly must be overhauled in
accordance with the manufacturer's instructions.
See TCM Form X30592 for TCM starters. See
Section 1-6, "Related Publications," for ordering
information.
STARTER ADAPTER
DRIVE ADAPTER
AND
ACCESSORY
2. See Figure 6-5, Compressor Mounting
Components, Starter and Starter Drive Adapter.
NOTE…
Do not clamp adapter housing in vise.
3. Place the starter shaft gear in a shielded vise.
Remove retaining ring (11) using snap ring pliers.
Discard retaining ring (11). See Figure 13-1,
"Starter Adapter Disassembly Tools" and Figure
6-5. Insert worm shaft tool into the worm shaft
slot and rotate the shaft counterclockwise to break
bearing (9) loose from the housing. Remove the
entire shaft assembly (8 through 10) from the
housing. Remove retaining ring (10). Separate
bearing (9) and shaft assembly (8). Discard
retaining ring (10) and bearing (9). It may be
necessary to use an arbor press to remove ball
bearing (9) from shaft (8). Remove bolt (60),
washer (59) and drive sheave (58).
4. Separate accessory drive adapter (33) from starter
adapter (2). Cut and remove lockwire from screws
(25). Remove screws (25), washers (24),
scavenge pump cover assembly (22, 23), bushing
(20), gear (19) and gear (21). Scavenge pump
covers and scavenge pump cover bushings with
indications of wear must be discarded. Remove
and discard woodruff key (27). Remove and
discard o-ring (18). Remove attaching hardware,
covers and gaskets (50 through 54, 65 through 67)
and bracket (62). Discard gaskets (50). Using
snap ring pliers disengage retaining (47) and slide
it back on shaft (44). Press shaft (44) through left
accessory drive pad opening. As shaft is pressed
out, retaining ring (47) and gear (48) will fall free
inside accessory drive adapter for removal.
11-2
Discard retaining ring (47). Key (45) must be
removed from shaft (44) and discarded.
5. Remove oil seals (35, 36). Bushings (37, 38) must
be removed using an arbor press. Remove gear
(46) and bushing (32). Remove gear (49),
bearings (55) and oil seal (56) from cover (57).
Discard bearings (55) and oil seal (56).
6. Remove shaft gear and worm wheel assembly
from starter adapter housing. Clamp starter shaft
gear teeth in shielded vise jaws. Rotate the worm
gear in a clockwise direction, at the same time
pull axially on the shaft gear to separate it from
the worm wheel and spring. Remove starter shaft
gear from the vise.
7. Clamp gear (13) in shielded vise. Remove spring
retaining screw (16) and tab washer (15). Discard
tab washer (15). Place a straight slot screwdriver
through a hole in the worm wheel (13) to catch
the end of spring (14). Rotate spring (14)
clockwise to release it from the land in the worm
wheel gear. Separate spring (14) from worm gear
(13).
8. Use a slide hammer and Borrough's 8093C
Bearing Puller or equivalent to remove needle
bearing (7) from housing (2).
11-2 COMPRESSOR
MOUNTING COMPONENTS,
STARTER AND STARTER
ADAPTER CLEANING
All starter adapter components and associated
hardware must be cleaned in accordance with the
instructions in Section 5-7, "General Cleaning," and
the following special instructions:
1. All bearings, sleeves, spacers, springs, gaskets,
o-rings, oil seals, lock washers, tab lock washers,
retainers, self locking nuts and the starter clutch
spring removed from the starter adapter must be
replaced 100% at overhaul. Cleaning of these
parts is not required.
2. The starter adapter housing cavities and oil
passages must be flushed with mineral spirit
solvent.
3. If the starter adapter or accessory drive housing is
immersed in an alkaline bath, when removed, it
must be sprayed with steam removing all traces of
alkaline. After the housing dries inspect for any
alkaline residues and if necessary re-spray with
steam until all alkaline is removed. The housing
exterior, cavities and all oil passages must be
thoroughly flushed with mineral spirit solvent
after any alkaline cleaning process has been used.
CAUTION…
Alkaline cleaning solutions will cause corrosion to
metals if not completely removed.
5. Clean the compressor mounting brackets, starter
sheave, scavenge pump cover and worm shaft
using mineral spirit solvent.
6. Clean gears that have bushings using mineral
spirit solvent and a brass wire brush. Gears with
bushings must not be cleaned using alkaline
solutions. Gears that do not have bushings can be
cleaned using mineral spirit solvent or by
immersion in a alkaline stripping bath if mineral
spirit solvent is not effective. After cleaning with
alkaline solution the gears must be sprayed with
steam removing all traces of alkaline. After steam
rinsing the gears must be thoroughly flushed with
mineral spirit solvent.
CAUTION…
Alkaline cleaning solutions will cause corrosion to
metals if not completely removed.
WARNING
Do not pressure blast gears with an abrasive
media. Blasting will remove surface
hardening.
11-3 COMPRESSOR BRACKETS,
STARTER AND STARTER
ADAPTER INSPECTION
VISUAL INSPECTION
The starter adapter, accessory drive adapter and
compressor mounting components must be visually
inspected in accordance with instructions in Section
5-8, "Visual Inspection." and the following areas:
1. The starter motor assembly must be overhauled in
accordance with the starter manufacturer's
instructions. See TCM Form X30592 for TCM
starters. See Section 1-6, "Related Publications,"
for ordering information.
2. Using a flashlight and a 10X magnifying glass,
visually inspect the exterior and the cavity of the
starter and accessory drive adapter housings for
cracks. Housings exhibiting cracks must be
discarded. Inspect the starter adapter cover and
scavenge pump cover for cracks. Adapter covers
and scavenge pump covers exhibiting cracks must
be discarded. Housing and cover oil passages
must be clear and free flowing. Housings and
covers with clogged oil passages that cannot be
opened must be discarded. Inspect all oil passages
for restrictions. Inspect all compressor mounting
components for cracks. Compressor mounting
components exhibiting cracks must be discarded.
3. Inspect the shaft gear, worm wheel gear and
worm gear teeth for signs of overheating and
excessive wear. Normal wear produces a fine
polish on the tooth thrust faces. Gears that have
alteration of the tooth profiles, score marks,
burning or pitting must be discarded. See Figure
8-1, “Gear Tooth Inspection,” for acceptable and
unacceptable gear tooth wear. See Figure 8-1,
“Gear Tooth Inspection,” for acceptable and
unacceptable gear tooth wear.
4. Inspect all nuts, bolts and screws for distorted or
stripped threads, corrosion and bending. Discard
any hardware exhibiting the above conditions.
5. Inspect the starter adapter housing studs for
distorted or stripped threads. Inspect studs for
corrosion, pitting, incomplete threads and
looseness. Replace studs with any of these
indications. Check studs with a tool makers
square for alignment. The starter adapter housing
studs must have their setting heights checked for
indications of backing out. See the following for
stud setting heights.
11-3
Chapter 11
ITEM
NO
1.
2.
3.
4.
5.
6.
LOCATION
THREAD SIZE
Stud, Starter Accessory Adapter to Starter Adapter
Stud, Starter Motor to Starter Adapter
Stud, Starter Motor to Starter Adapter
Dowel, Starter Adapter to Crankcase
Stud, Gearshaft Housing to Accessory Adapter
Dowel, Gearshaft Housing to Accessory Adapter
5/16-18 X 5/16-24 X 1.25
3/8 - 16 X 3/8 - 24 X 1.53
3/8 - 16 X 3/8 - 24 X 1.75
---1/4 - 20 X 1/4 - 28 X 1.56
----
SETTING
HEIGHT
1.30
1.00
1.22
.17
1.03
.27
QTY.
1
1
1
2
4
2
FIGURE 11-1. STARTER ADAPTER STUD SETTING HEIGHTS
FLUORESCENT PENETRANT INSPECTION
Aluminum alloy components such as the starter
adapter housing, accessory drive adapter and
gearshaft housing must be fluorescent penetrant
inspected by a certified technician in accordance
with Section 5-12, "Fluorescent Penetrant
Inspection." Housings or covers exhibiting cracks
must be discarded.
11-5
MAGNETIC PARTICLE INSPECTION
The shaft gear, worm shaft, worm gear, bevel gears and
drive shaft must be magnetic particle inspected by a
certified technician in accordance with instructions in
Section 5-9, "Magnetic Particle Inspection." Gears or
shafts exhibiting cracks must be discarded.
Chapter 11
DIMENSIONAL INSPECTION
The following new parts limits must be used for dimensional inspection. Components that do not meet the
following specifications must be discarded.
All components must be thoroughly cleaned and air dried prior to dimensional inspection.
REF.
NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
DESCRIPTION
Starter shaftgear in bushing ............................................................ Diameter:
Starter shaftgear front (bearing) journal ......................................... Diameter:
Starter shaftgear in needle bearing ................................................. Diameter:
Starter shaftgear in accessory drive adapter bushing ..................... Diameter:
Bushing in adapter cover ................................................................ Diameter:
Gearshaft housing oil seal bore ...................................................... Diameter:
Starter adapter cover pilot in adapter housing................................ Diameter:
Worm wheel gear....................................................................End Clearance:
Worm wheel drum outside ............................................................. Diameter:
Clutch spring on Starter Shaftgear
drum .50-.56 from drum end .......................................................... Diameter:
Starter shaftgear drum..................................................................... Diameter:
Starter clutch spring outside ........................................................... Diameter:
Starter clutch spring inside ............................................................. Diameter:
Needle bearing bore ........................................................................ Diameter:
Clutch spring on worm wheel drum ............................................... Diameter:
From center line of worm gearshaft
to starter adapter thrust pads ...........................................................................:
Worm gearshaft in ball bearing ...................................................... Diameter:
Ball bearing in starter adapter housing........................................... Diameter:
Starter pilot to starter drive adapter ................................................ Diameter:
Starter drive tongue to worm shaft drive slot .........................Side Clearance:
Needle bearing to worm gear shaft................................................. Diameter:
Worm gearshaft............................................................................... Diameter:
Starter gear to crankshaft gear
Backlash:
Starter worm wheel gear and worm shaft gear............................... Backlash:
Scavenge pump driven gear on shaft.............................................. Diameter:
Scavenge pump gears in adapter .................................................... Diameter:
Scavenge pump drive gear on starter shaftgear.............................. Diameter:
Scavenge pump driven gear to drive gear ...................................... Backlash:
R/H side accessory drive bushing in adapter ................................. Diameter:
R/H accessory drive shaft end in bushing ...................................... Diameter:
L/H side accessory drive bushing in adapter.................................. Diameter:
L/H accessory drive shaft end in bushing ...................................... Diameter:
Driver bevel gear on shaftgear........................................................ Diameter:
Accessory drive shaft...................................................................... Diameter:
Accessory drive shaft...................................................................... Diameter:
Accessory drive shaft...................................................................... Diameter:
Driven bevel gear inside ................................................................. Diameter:
R/H oil seal bore ............................................................................. Diameter:
L/H oil seal bore.............................................................................. Diameter:
NEW PARTS
MIN.
MAX.
0.001L
0.003L
1.059
1.060
0.0005L
0.0029L
0.0005L
0.002L
0.003T
0.005T
1.574
1.576
0.001L
0.003L
0.0025L
0.0115L
See Figure 11-2B
0.008T
0.012T
See Figure 11-2C
Replace 100%
Replace 100%
.7485
.7495
0.015T
0.022T
0.252
0.0004T
0.0004L
0.001L
0.001T
0.001L
0.0065L
0.010L
0.021L
0.0005L
0.0029L
0.5620
0.5626
0.008
0.012
0.009
0.013
0.0005L
0.0025L
0.0055L
0.0080L
0.0002L
0.0017L
0.014
0.0218
0.002T
0.004T
0.001L
0.003L
0.002T
0.004T
0.001L
0.003L
0.0017L
0.002L
1.0600
1.0610
.9360
.9370
.8100
.8110
.9370
.9380
1.249
1.251
1.500
1.502
11-5
Chapter 11
REF.
NO
40.
41.
42.
DESCRIPTION
Driven and driver bevel gears .........................................................Backlash:
Gearshaft housing bearing bore.......................................................Diameter:
Sheave gearshaft .............................................................................Diameter:
FIGURE 11-2A. STARTER ADAPTER FITS & LIMITS
11-6
NEW PARTS
MIN. MAX.
0.004
0.006
1.0610
1.0620
0.8120
0.8125
Chapter 11
FIGURE 11-2B. SHAFTGEAR DRUM DIMENSIONS
DESCRIPTION
“A" DIAMETER
MIN.
MAX.
1.948
1.950
1.933
1.935
New Shaftgear Drum
0.015 Undersize
"B" DIAMETER
MIN.
MAX.
1.9365
1.9385
1.9215
1.9235
FIGURE 11-2C. WORM WHEEL DRUM DIMENSIONS
DESCRIPTION
New Worm Wheel Drum
0.015 Undersize
“A" DIAMETER
MIN.
MAX.
1.9365
1.9385
1.9215
1.9235
"B" DIAMETER
MIN.
MAX.
1.955
1.960
1.940
1.945
11-7
Chapter 11
NEW PARTS DIMENSIONS
PART NAME
Starter Worm Drive Shaft
Starter Shaft Gear
Starter Clutch Drum
Scavenge Pump
Starter Clutch Spring
FEATURE
Diameter
Needle bearing hole in starter adapter diameter
Front journal diameter
Drum diameter
Clutch drum spring support diameter
Inside diameter
Cover Inside diameter
Outside diameter
Inside diameter
11-4 COMPRESSOR
MOUNTING COMPONENT,
STARTER AND STARTER
ADAPTER REPAIR AND
REPLACEMENT
Any starter or starter adapter component found to be
worn beyond new parts limits or failing to meet the
inspection criteria in Section 11-3 must be replaced
unless repair is possible with the following
instructions:
Starter adapter housings, accessory drive adapter
housings, adapter covers, shaft gears, worm wheel
gears, worm gears, worm gear shafts or accessory
drive shafts exhibiting cracks must be discarded and
replaced. Accessory mount brackets exhibiting cracks
must be discarded and replaced. Scavenge pump
covers worn beyond specifications must be discarded
11-8
NEW DIMENSIONS
(INCHES)
0.5620 - 0.5626
0.7485 - 0.7495
1.059 - 1.060
1.9348 - 1.9385
1.9365 - 1.9385
1.3115 - 1.3125
1.2485 - 1.2495
2.267 - 2.282
1.938 - 1.940
and replaced. Accessory drive sheaves with any
indications of wear must be discarded and replaced.
Scavenge pump gears with any indications of wear
must be discarded and replaced.
The starter adapter housing worm shaft needle bearing
must be replaced using the following procedure and
special tools:
1. Arbor Press.
2. TCM Starter Adapter Housing Needle
Bearing Installer or equivalent. See Figure
11-3.
See Figure 6-4, "Compressor Mounting Components,
Starter
And
Starter
Adapter
Assembly
(TSI0-360-RB)." Using the specified tools install a
new needle bearing (7) into the starter adapter
housing. Press the new bearing in until it is 0.03
thousandths of an inch below inner surface.
Chapter 11
FIGURE 11-3. STARTER ADAPTER NEEDLE BEARING INSTALLER
11-9
Chapter 11
FIGURE 11-3. STARTER ADAPTER NEEDLE BEARING INSTALLER (continued)
11-10
Chapter 11
FIGURE 11-4. ACCESSORY DRIVE ADAPTER COVER NEEDLE BEARING
INSTALLATION
Using a blind bearing puller, remove needle bearing
(23) from scavenge pump cover (22) and discard.
Using an arbor press and an installation tool
conforming with the specifications in Figure 11-4,
"Scavenge Pump Cover Needle bearing Installation,"
install a new needle bearing (23) in scavenge pump
cover (22) to the required specifications.
discard. Using the same tools, install a new roller
bearing (12) in worm wheel (22).
Using an arbor press and proper size tool, remove
roller bearing (12) from worm wheel (13) and
Section 5-19,"Application Of Accelagold," applies to
all aluminum alloy castings, sheet metal and tubing.
Any studs found to be damaged or loose must be
replaced in accordance with the instructions in Section
5-22. See Figure 11-1," Starter Adapter Stud Setting
Heights," for proper stud setting heights.
11-11
Chapter 11
11-5 COMPRESSOR
MOUNTING COMPONENT,
STARTER AND STARTER
ADAPTER SUB-ASSEMBLY
TSI0-360-RB
1. See Figure 6-4, "Compressor brackets, Starter
And Starter Adapter TSI0-360-RB." Press new
bearing (9) onto worm shaft and gear assembly
(8). Press bearing until seated against flange.
Install new retaining ring (10). Coat worm gear
teeth using clean Molyshield grease. Insert
assembly into adapter housing and install new
retaining ring (11). Insure that retaining rings are
properly seated.
2. Install new clutch spring (14) on worm wheel
(13). Turn spring so it tends to unwind until offset
end drops into the worm wheel gear land. Position
spring on gear so screw notch is aligned with
screw hole in gear web. Install new tab washer
(15) and screw (16). Torque screw (16) to
75.0-85.0 inch pounds torque, and bend tab up
against screw head.
3. Lubricate spring and shaft gear liberally with
clean 50 weight aviation engine oil. Press worm
wheel and spring assembly onto shaft gear (17).
Insert shaft gear and worm wheel assembly into
adapter. Make sure worm wheel and worm gear
teeth are aligned.
4. Using an arbor press install new bushings (32, 37
and 38) in accessory drive adapter (33). Apply
TCM Gasket Maker to the outside diameter of
new uncoated oil seals. Install new oil seals (35,
36) in accessory drive adapter (33). Clean
accessory drive adapter removing any debris.
Lubricate bushings and oil seals with clean 50
weight aviation engine oil. Lubricate new or
serviceable scavenge pump gears (19, 21) shafts,
ends and teeth with clean Molyshield grease.
Lubricate the scavenge pump housing and cover
gear contact areas using clean Molyshield grease.
Install scavenge gears (19, 21) in accessory drive
adapter (33). Install new or serviceable scavenge
pump cover (22) on accessory drive adapter (33)
and secure using washers (24) and screws (25).
Torque screws (25) to 75-85 inch pounds and
11-12
lockwire in accordance with Section 4-2. Insure
that gears (19, 21) rotate freely.
5. Install bracket (63), lifting eye (64), new lock
washers (69), washers (68) and bolts (71, 73) on
accessory drive adapter (33). Center scavenge
pump gear (21) inside accessory drive adapter
(33). Using new o-ring (18), install accessory
drive adapter on starter adapter housing and
insure that shaftgear (17) has completely engaged
scavenge pump gear (21). As the accessory drive
adapter is installed insure bolts (71, 73) line up
and slide through starter adapter housing. Secure
the brackets, lifting eye and accessory drive
adapter to the starter adapter housing using
washer (68), new lockwasher (69) and nut (72).
Snug but do not torque nut (69) at this time. Coat
bevel gear teeth with clean Molyshield grease.
Using a new woodruff key (27), install bevel gear
(46) on end of shaftgear (17) inside of accessory
drive adapter (33). Position gear (48) inside
accessory drive adapter. Using a new square key
(45), install drive shaft (44) in accessory drive
adapter (33). Insure that shaft (44) properly
engages bevel gear (48) and that key (45) is
properly positioned. Install a new retaining ring
(47) on shaft (44) and insure that it is properly
seated. Inspect bevel gears for a backlash of .004
to .006.
6. Apply TCM Gasket Maker to the outside
diameter of new uncoated oil seals. Install new oil
seal (56) and new bearings (55) in accessory drive
housing (57). Lubricate bevel gear (49) with clean
50 weight aviation engine oil. Install bevel gear
(49) in accessory drive cover (57). Apply
Permatex and silk thread to accessory drive
housing flange (57) in accordance with Figure
11-5, "Accessory Drive Housing Threading
Procedure." Install accessory drive housing (57)
on accessory drive adapter and secure using
washers (65) and nuts (66).Torque nuts (66) to
75-85 inch pounds. Install bracket (62) on
accessory drive housing (57) and secure
Chapter 11
using washers(65) and nuts (67). Torque nuts (67)
to 75-85 inch pounds and lockwire in accordance
with Section 4-2. Install drive sheave (58) using
washer (59) and bolt (60). Place the starter shaft
gear in a shielded vise and torque bolt (60) to
600-650 inch pounds.
NOTE…
7. Install new gaskets (50), covers ((51) and secure
using washers (52), new lock washers (53) and
nuts (54). Torque nuts (54) to 75-85 inch pounds.
8. Store the compressor mounting components,
starter and starter adapter in a clean protected
area until final engine assembly.
Bolt (60) threads are left hand.
FIGURE 11-5. ACCESSORY DRIVE HOUSING THREADING PROCEDURE
11-13
Chapter 11
INTENTIONALLY
LEFT
BLANK
11-14
Chapter 12
CHAPTER 12
ELECTRICAL CHARGING SYSTEM
SECTION
12-1
12-2
12-3
12-4
12-5
12-6
12-7
12-8
12-9
12-10
PAGE
Belt Driven Alternator Disassembly................................................ 12-2
Electrical Charging System Component Cleaning .......................... 12-2
Electrical Charging System Component Inspection........................ 12-2
Electrical Charging System Component Replacement.................... 12-2
Electrical Charging System Component Sub Assembly ................. 12-2
Direct Drive Alternator Removal..................................................... 12-3
Electrical Charging System Component Cleaning .......................... 12-3
Electrical Charging System Component Inspection........................ 12-3
Electrical Charging System Component Replacement.................... 12-5
Electrical Charging System Component Sub Assembly ................. 12-5
FIGURE
12-1
12-2
12-3
PAGE
One Piece Coupling.......................................................................... 12-4
Slippage Inspection Tool.................................................................. 12-4
Alternator Drive Component Assembly .......................................... 12-6
12-1
Chapter 12
12-1 BELT DRIVEN
ALTERNATOR DISASSEMBLY
1. The alternator assembly must be overhauled in
accordance with the alternator manufacturer's
instructions.
12-2 ELECTRICAL
CHARGING SYSTEM
COMPONENT CLEANING
The alternator mount bracket, adjusting bracket and
associated hardware must be cleaned in accordance
with the instructions in Section 5-7, "General
Cleaning," and the following special instructions:
1. All lock washers and self locking nuts removed
from the electrical charging system must be
replaced 100% at overhaul. Cleaning of these
parts is not required.
12-3 ELECTRICAL
CHARGING SYSTEM
COMPONENT INSPECTION
VISUAL INSPECTION
The visual inspection must be performed in
accordance with the instructions in Section 5-8,
"Visual Inspection," and the following:
1. Inspect all nuts, bolts and screws for distorted or
stripped threads, corrosion and bending. Discard
any hardware exhibiting the above conditions.
FLUORESCENT PENETRANT INSPECTION
The alternator mount bracket and adjusting bracket
must be thoroughly cleaned prior to fluorescent
penetrant inspection. All oil and preservative material
must be removed.
The alternator mount bracket and adjusting bracket
must be fluorescent penetrant inspected by a certified
technician in accordance with Section 5-12,
"Fluorescent Penetrant Inspection." Cracks in the
brackets are not acceptable or repairable. Alternator
mount or adjusting brackets that exhibit cracks or
indications of cracks must be discarded.
12-2
MAGNETIC PARTICLE INSPECTION
The alternator pivot bolt must be magnetic particle
inspected by a certified technician in accordance with
the instructions in Section 5-9, "Magnetic Particle
Inspection." Cracked pivot bolts must be discarded.
12-4 ELECTRICAL
CHARGING SYSTEM
COMPONENT REPAIR AND
REPLACEMENT
Any electrical charging system component failing to
meet the inspection criteria in Section 12-3 must be
replaced unless repair is possible with the following
instructions:
1. Any electrical charging system hardware found to
have any of the discrepancies listed in Section
12-3 must be replaced.
2. Replace all electrical charging system parts listed
in Section 5-6, "100% Replacement Parts."
3. Section 5-19, "Application Of Accelagold,"
applies to all aluminum alloy castings, sheet metal
and tubing.
12-5 ELECTRICAL CHARGING
SYSTEM SUB-ASSEMBLY
Note…All electrical charging system components
must be clean and free of debris before assembly.
1. After the alternator has been properly overhauled,
store it in a clean protected area along with its
associated components until final engine
assembly.
Chapter 12
NOTE…
The following information is for L/TSI0-360-RB
engines that utilize a direct drive alternator.
12-6 DIRECT DRIVE
ALTERNATOR DISASSEMBLY
(See Figure 6-7.)
1. Remove cotter pin (7) and nut (6). Remove gear
hub assembly from alternator shaft. Remove and
discard woodruff key (8).
2. Using a blind oil seal puller remove and discard
oil seal (9).
3. Remove and discard o-ring (10).
4. The alternator assembly must be overhauled in
accordance with the alternator manufacturer's
instructions.
12-7
ELECTRICAL
CHARGING SYSTEM
COMPONENT CLEANING
All electrical charging system components and
associated hardware must be cleaned in accordance
with the instructions in Section 5-7, "General
Cleaning," and the following special instructions:
1. All gaskets, o-rings, oil seals, lock washers,
woodruff keys and self-locking nuts removed
from the electrical charging system must be
replaced 100% at overhaul. Cleaning these parts
is not required.
2. Clean gears that have bushings using mineral
spirit solvent and a brass wire brush. Gears with
bushings must not be cleaned using alkaline
solutions. Gears that do not have bushings can be
cleaned using mineral spirit solvent or by
immersion in an alkaline stripping bath if mineral
spirit solvent is not effective. After cleaning with
alkaline solution the gears must be sprayed with
steam removing all traces of alkaline. After steam
rinsing, the gears must be thoroughly flushed with
mineral spirit solvent.
CAUTION…
Alkaline cleaning solutions will cause corrosion to
metals if not completely removed.
WARNING
Do not pressure blast gears with an abrasive
media. Blasting will remove surface
hardening.
12-8 ELECTRICAL CHARGING
SYSTEM COMPONENT
INSPECTION
VISUAL INSPECTION
The visual inspection must be performed in
accordance with the instructions in Section 5-8,
"Visual Inspection." Special attention must be given
to the following components and areas:
Drive Hub
1. Inspect gear teeth for signs of overheating and
excessive wear. Normal wear produces a fine
polish on the tooth thrust faces. Gears that have
alteration of the tooth profiles, score marks,
burning or pitting must be discarded. See Figure
8-1, “Gear Tooth Inspection,” for acceptable and
unacceptable gear tooth wear.
FLUORESCENT PENETRANT INSPECTION
Fluorescent penetrant inspection must be performed
on all aluminum alloy electrical charging system
components by a certified technician in accordance
with instructions in Section 5-12, "Fluorescent
Penetrant Inspection." Any components exhibiting
cracks must be discarded.
MAGNETIC PARTICLE INSPECTION
The alternator drive hub (gear) assembly must be
magnetic particle inspected by a certified technician in
accordance with the instructions in Section 5-9,
"Magnetic Particle Inspection." Drive hubs exhibiting
cracks must be discarded.
12-3
Chapter 12
ALTERNATOR DRIVE HUB INSPECTION (See
Figures 12-1 and 12-2.)
1. The P/N 635796 single piece coupling is designed
to slip when abnormal torque is required to rotate
the alternator/generator. This can prevent internal
engine damage in the event of an
alternator/generator seizure. Inspect this coupling
for shearing or tearing of the elastomeric (rubber)
element. Replace coupling if damage is observed.
The following test must be performed at engine
overhaul or when slippage is suspected.
a. With the coupling removed from the
alternator/generator, place the coupling body
in the protected jaws of a vise.
b. Figure 12-2 provides necessary dimensions to
produce a tool for checking coupling slippage
torque.
c. Install the tool over the coupling gear and
apply 100 inch pounds of torque. No slippage
can occur at or below 100 inch pounds of
torque. Replace couplings that fail this test.
FIGURE 12-1. ONE PIECE COUPLING
FIGURE 12-2. SLIPPAGE INSPECTION TOOL
12-4
12-9 ELECTRICAL CHARGING
SYSTEM COMPONENT REPAIR
AND REPLACEMENT
Any electrical charging system component failing to
meet the inspection criteria in Section 12-3 must be
replaced unless repair is possible with the following
instructions:
1. Repair and replacement procedures for the
alternator assembly must be performed in
accordance with the alternator manufacturer's
instructions.
2. Replace all electrical charging system parts listed
in Section 5-6, "100% Replacement Parts."
3. Place the toothed portion of drive hub gear in
shielded vise jaws and tighten vise only enough to
prevent rotation during torquing of nut. Using a
currently calibrated torque wrench, torque the P/N
530412 nut to 175 inch pounds. Torque may be
increased to a maximum of 200 inch pounds to
align castellated nut with the cotter pin hole. If
alignment cannot be achieved with torque
between 175 - 200 inch pounds, replace nut. Do
not over or under torque! Install new P/N
MS24665-151 cotter pin and secure in accordance
with Section 4-4, "Cotter Pin Procedure."
4. Store the alternator and attaching hardware in a
clean protected area until final engine assembly.
3. Section 5-19, "Application Of Accelagold,"
applies to all aluminum alloy castings, sheet metal
and tubing.
12-10 ELECTRICAL CHARGING
SYSTEM COMPONENT
SUB-ASSEMBLY
NOTE…
All electrical charging system components must be
clean and free of debris before assembly.
1. See Figure 6-7. Install a new oil seal (9) in
alternator (4) using an arbor press and a tool
conforming with the specifications in Figure 12-3.
2. See Figure 6-7. Lubricate o-ring (10) with clean
50 weight aviation engine oil. Install a new o-ring
(10) on alternator shaft.
12-5
Chapter 12
FIGURE 12-3. ALTERNATOR DRIVE COUPLING COMPONENT ASSEMBLY
12-6
Chapter 13
CHAPTER 13
STARTING SYSTEM
SECTION
13-1
13-2
13-3
13-4
13-5
13-6
13-7
FIGURE
13-1
13-2
13-3
PAGE
Starter And Starter Adapter Disassembly............. 13-2
Starter Motor Overhaul......................................... 13-3
Starter And Starter Adapter Cleaning................... 13-3
Starter And Starter Adapter Inspection ................ 13-4
Starter And Starter Adapter Repair
And Replacement.................................................. 13-8
Optional Starter And Starter Adapter
Sub-assembly TSI0-360-RB................................. 13-8
Starter And Starter Adapter
Sub-assembly LTSI0-360-RB .............................. 13-9
PAGE
Starter Adapter Disassembly Tools ...................... 13-2
Starter Adapter Stud Setting Heights.................... 13-5
Starter Adapter Fits & Limits .............................. 13-7
NOTE…
See Chapter 11 for TSI0-360-RB Standard Starter Adapter And Freon Compressor Mounting Equipment.
13-1
Chapter 13
13-1 STARTER ADAPTER
DISASSEMBLY
OPTIONAL STARTER AND STARTER
ADAPTER DISASSEMBLY TSI0-360-RB (SEE
FIGURE 6-8)
1. Place the starter shaft gear in a shielded vise.
Remove retaining ring (11) using snap ring pliers.
Insert worm shaft tool into the worm shaft slot
and rotate the shaft counterclockwise to break
bearing (9) loose from the housing. Remove the
entire shaft assembly (8 through 10) from the
housing. Remove retaining ring (10). Separate
bearing (9) and shaft assembly (8). Discard
retaining rings (10, 11) and bearing (9). It may be
necessary to use an arbor press to remove ball
bearing (9) from shaft (8).
2. Separate cover (19) from adapter housing (2).
Cover (19) may require a few taps with a soft
mallet to remove.
3. Cut and remove lockwire from screws (33).
Remove screws (33), washers (32), scavenge
pump cover assembly (29), gear (25), bushing
(26) and gear (27). Remove and discard woodruff
key (28). Scavenge pump covers and scavenge
pump cover bushings with indications of wear
must be discarded. Remove and discard o-ring
(18).
4. Use an arbor press and proper size tool to remove
bushing (20) and oil seal (21) from cover (19).
5. Remove shaft gear and worm wheel assembly
from adapter housing. Clamp starter shaft gear
teeth in shielded vise jaws. Rotate the worm gear
in a clockwise direction, at the same time pull
axially on the shaft gear to separate it from the
worm wheel and spring. Remove starter shaft gear
from the vise.
6. Clamp worm wheel gear (13) in shielded vise.
Remove spring retaining screw (16) and tab
washer (15). Place a straight slot screwdriver
through a hole in the worm wheel (13) to catch
the end of spring (14). Rotate spring (14)
clockwise to release it from the land in the worm
wheel gear. Separate spring (14) from worm
wheel gear (13). Remove roller bearing (12) from
worm wheel gear (13).
7. Use a slide hammer and Borrough's 8093C
Bearing Puller or equivalent to remove needle
bearing (7) from housing (2).
FIGURE 13-1. STARTER ADAPTER DISASSEMBLY TOOLS
13-2
Chapter 13
STARTER AND STARTER ADAPTER
DISASSEMBLY LTSI0-360-RB (SEE FIGURE 69)
1. Place the starter shaft gear in a shielded vise.
Remove retaining ring (14) using snap ring pliers.
Insert worm shaft tool into the worm shaft slot
and rotate the shaft counterclockwise to break
bearing (13) loose from the housing. Remove the
entire shaft assembly (8 through 12) from the
housing. Remove pin (12), bushing (11) and
separate shaft (8), Gear (10) and woodruff key
(9). Discard woodruff key (9). Separate bearing
(13) and shaft assembly (8). It may be necessary
to use an arbor press to remove ball bearing (13)
from shaft (8). Discard retaining ring (14) and
bearing (13).
2. Separate cover (22) from adapter housing (2).
Cover (22) may require a few taps with a soft
mallet to remove.
3. Cut and remove lockwire from screws (35).
Remove screws (35), washers (34), scavenge
pump cover assembly (31), gear (27), bushing
(28) and gear (29). Remove and discard woodruff
key (30). Scavenge pump covers and scavenge
pump cover bushings with indications of wear
must be discarded. Remove and discard o-ring
(21).
4. Use an arbor press and proper size tool to remove
bushing (23) and oil seal (24) from cover (22).
5. Remove shaft gear and worm wheel assembly
from adapter housing. Clamp starter shaft gear
teeth in shielded vise jaws. Rotate the worm gear
in a counterclockwise direction, at the same time
pull axially on the shaft gear to separate it from
the worm wheel and spring. Remove starter shaft
gear from the vise.
6. Clamp worm wheel gear (16) in shielded vise.
Remove spring retaining screw (19) and tab
washer (18). Place a straight slot screwdriver
through a hole in the worm wheel (16) to catch
the end of spring (17). Rotate spring (17)
counterclockwise to release it from the land in the
worm wheel gear. Separate spring (17) from
worm wheel gear (16). Remove roller bearing
(15) from worm wheel gear (16).
7. Use a slide hammer and Borrough's 8093C
Bearing Puller or equivalent to remove needle
bearing (7) from housing (2).
13-2 STARTER MOTOR
OVERHAUL
The starter motor assembly must be overhauled in
accordance with the manufacturer's instructions. See
TCM Form X30592 for TCM starters. See Section
1-6, "Related Publications," for ordering information.
13-3 STARTER AND STARTER
ADAPTER CLEANING
All starter adapter components and associated
hardware must be cleaned in accordance with the
instructions in Section 5-7, "General Cleaning," and
the following special instructions:
1. All bushings, bearings, sleeves, spacers, springs,
gaskets, o-rings, oil seals, lock washers, tab lock
washers, retainers, self locking nuts and the starter
clutch spring removed from the starter adapter
must be replaced 100% at overhaul. Cleaning of
these parts is not required.
2. The starter adapter housing and scavenge pump
housing cavities and oil passages must be flushed
with mineral spirit solvent.
3. If the starter adapter housing or scavenge pump
housing are immersed in an alkaline bath, when
removed, they must be sprayed with steam
removing all traces of alkaline. After the housing
dries inspect it for any alkaline residues and if
necessary re-spray with steam to remove. The
housing exterior, cavities and all oil passages
must be thoroughly flushed with mineral spirit
solvent after any alkaline cleaning process has
been used.
CAUTION…
Alkaline cleaning solutions will cause corrosion to
metals if not completely removed.
4. Clean the starter sheave, scavenge pump cover
and worm shaft using mineral spirit solvent.
5. Clean gears that have bushings using mineral
spirit solvent and a brass wire brush. Gears with
bushings must not be cleaned using alkaline
solutions. Gears that do not have bushings can be
6. cleaned using mineral spirit solvent or by
immersion in a alkaline stripping bath if mineral
spirit solvent is not effective. After cleaning with
alkaline solution the gears must be sprayed with
13-3
Chapter 13
steam removing all traces of alkaline. After steam
rinsing the gears must be thoroughly flushed with
mineral spirit solvent.
CAUTION…
Alkaline cleaning solutions will cause corrosion to
metals if not completely removed.
WARNING
Do not pressure blast gears with an abrasive
media. Blasting will remove surface
hardening.
13-4 STARTER AND STARTER
ADAPTER INSPECTION
VISUAL INSPECTION
The starter adapter components must be visually
inspected in accordance with instructions in Section
5-8, "Visual Inspection." Special attention must be
given to the following components and areas:
1. Using a flashlight and a 10X magnifying glass
visually inspect the exterior and the cavity of the
starter adapter housing and scavenge pump
housing for cracks. Housings exhibiting cracks
must be discarded. Using a flashlight and a 10X
13-4
magnifying glass visually inspect the scavenge
pump cover and bushing. Scavenge pump covers
and bushings exhibiting any indications of wear
must be discarded and replaced. Inspect the starter
adapter covers for cracks. Adapter covers
exhibiting cracks must be discarded. Inspect all
oil passages for restrictions. Housing oil passages
must be clear and free flowing. Housings with
clogged oil passages that cannot be opened must
be discarded.
2. Inspect the shaft gear, worm wheel gear and
worm gear teeth for signs of overheating and
excessive wear. Normal wear produces a fine
polish on the tooth thrust faces. Gears that have
alteration of the tooth profiles, score marks,
burning or pitting must be discarded. See Figure
8-1. “Gear Tooth Wear,” for acceptable and
unacceptable gear tooth wear.
3. Inspect the starter adapter housing and scavenge
pump housing studs for distorted or stripped
threads. Inspect studs for corrosion, pitting,
incomplete threads and looseness. Replace studs
with any of these indications. Check studs with a
tool makers square for alignment. The starter
adapter housing studs must have their setting
heights checked for indications of backing out.
See the following for stud setting heights.
Chapter 13
ITEM
LOCATION
NO
1.
Stud,, Starter Accessory Adapter to Starter Adapter
2.
Stud,, Starter Motor to Starter Adapter
3.
Stud,, Starter Motor to Starter Adapter
4.
Dowel,, Starter Adapter to Crankcase
5.
Stud,, Cover to Scavenge Pump Housing
6.
Stud,, Cover to Scavenge Pump Housing
FLUORESCENT PENETRANT INSPECTION
THREAD SIZE
5/16-18 X 5/16-24 X 1.25
3/8 - 16 X 3/8 - 24 X 1.53
3/8 - 16 X 3/8 - 24 X 1.75
---1/4 - 20 X 1/4 - 28 X 1.19
1/4 - 20 X 1/4 - 28 X 1.12
SETTING
HEIGHT
.78
1.00
1.22
.17
.69
.62
QTY.
1
1
1
2
4
4
FIGURE 13-2. STARTER ADAPTER STUD SETTING HEIGHTS
Aluminum alloy components such as the starter
adapter housing and scavenge pump housing must be
fluorescent penetrant inspected by a certified
technician in accordance with Section 5-12,
"Fluorescent Penetrant Inspection." Housings or
covers exhibiting cracks must be discarded.
MAGNETIC PARTICLE INSPECTION
The shaft gear, worm shaft and worm gear must be
magnetic particle inspected by a certified technician in
accordance with instructions in Section 5-9,
"Magnetic Particle Inspection." Gears or shafts
exhibiting
cracks
must
be
discarded.
13-5
Chapter 13
DIMENSIONAL INSPECTION
The following new parts limits must be used for dimensional inspection. Components that do not meet the
following specifications must be discarded.
All components must be thoroughly cleaned and air dried prior to dimensional inspection.
STARTER AND STARTER ADAPTER FITS & LIMITS
REF.
NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
13-6
DESCRIPTION
Starter shaftgear in bushing.............................................................................. Diameter:
Starter shaftgear front (bearing) journal............................................................ Diameter:
Starter shaftgear in needle bearing .................................................................. Diameter:
Scavenge pump gear shaft in cover bushing ................................................... Diameter:
Bushing in adapter cover .................................................................................. Diameter:
Adapter cover oil seal bore ............................................................................... Diameter:
Starter adapter Cover Pilot In Adapter Housing ............................................... Diameter:
Worm wheel gear.....................................................................................End Clearance:
Clutch spring on Starter Shaftgear drum
.50-.56 from drum end ...................................................................................... Diameter:
Starter shaftgear drum...................................................................................... Diameter:
Starter clutch spring outside ............................................................................. Diameter:
Starter clutch spring inside................................................................................ Diameter:
Clutch spring on worm wheel drum .................................................................. Diameter:
Worm wheel drum outside................................................................................ Diameter:
Worm wheel drum inside .................................................................................. Diameter:
From center line of worm gearshaft
to starter adapter thrust pads.............................................................................................:
Needle bearing bore ......................................................................................... Diameter:
Starter worm drive shaft.................................................................................... Diameter:
Ball bearing in starter adapter........................................................................... Diameter:
Worm gearshaft in ball bearing......................................................................... Diameter:
Starter pilot to starter drive adapter .................................................................. Diameter:
Starter drive tongue to worm shaft drive slot .........................................Side Clearance:
Needle bearing to worm gear shaft................................................................... Diameter:
Starter gear to crankshaft gear......................................................................... Backlash:
Starter worm wheel gear and worm gear ......................................................... Backlash:
Scavenge pump driven gear on shaft............................................................... Diameter:
Scavenge pump drive gear in adapter.............................................................. Diameter:
Scavenge pump gears in adapter..................................................................... Diameter:
Scavenge pump gears in adapter............................................................End Clearance:
Scavenge pump drive gear in starter shaftgear................................................ Diameter:
Starter shaftgear in scavenge pump cover....................................................... Diameter:
Starter shaftgear rear journal............................................................................ Diameter:
Scavenge pump driven gear to drive gear........................................................ Backlash:
NEW PARTS
MIN.
MAX
0.001L
0.003L
1.059
1.060
0.0005L
0.0029L
0.0005L
0.0035L
0.001T
0.003T
1.249
1.251
0.001L
0.003L
0.0025
0.0115
0.008T
0.012T
See Figure 11-2B
Replace 100%
Replace 100%
0.015T
0.022T
See Figure 11-2C
1.3115
1.3125
0.252
0.7485
0.7495
0.5620
0.5626
0.001L
0.001T
0.0004T
0.0004L
0.001L
0.0065L
0.010L
0.021L
0.0005L
0.0029L
0.008
0.012
0.009
0.013
0.0005L
0.0025L
0.0005L
0.0025L
0.0055L
0.0080L
0.0010
0.0035
0.0010L
0.0030L
0.0005L
0.0025L
0.9995
1.0000
0.0140
0.0218
Chapter 13
FIGURE 13-3. STARTER ADAPTER FITS AND LIMITS
13-7
Chapter 13
PART NAME
Starter Worm Drive Shaft
Starter Shaft Gear
Starter Clutch Drum
Starter Clutch Spring
NEW PARTS DIMENSIONS
FEATURE
Diameter
Needle bearing hole in starter adapter diameter
Front journal diameter
Drum diameter
Clutch drum spring support diameter
Inside diameter
Outside diameter
Inside diameter
13-5 STARTER AND STARTER
ADAPTER REPAIR AND
REPLACEMENT
Any starter or starter adapter component found to be
worn beyond new parts limits or failing to meet the
inspection criteria in Section 13-4 must be replaced
unless repair is possible with the following
instructions:
The starter motor assembly must be overhauled in
accordance with the manufacturer's instructions. See
TCM Form X30592 for TCM starters. See Section
1-5, "Related Publications," for ordering information.
Starter adapter housings, scavenge pump housings,
adapter covers, shaft gears, worm wheel gears, worm
gears, worm gear shafts or accessory drive shafts
exhibiting cracks must be discarded and replaced.
Accessory mount brackets and lifting eyes exhibiting
cracks must be discarded and replaced. Scavenge
pump covers and bushings with any indications of
wear must be discarded and replaced. Accessory drive
sheaves with any indications of wear must be
discarded and replaced. Scavenge pump gears with
any indications of wear must be discarded and
replaced.
The starter adapter housing worm shaft needle bearing
must be replaced using the following procedure and
special tools:
1. Arbor Press.
2. TCM Starter Adapter Housing Roller Bearing
Installer or equivalent.
See Figure 11-3 ,"Starter Adapter Needle Bearing
Installer." Using the specified tools install a new roller
bearing (7) into the starter adapter housing. Press the
13-8
NEW DIMENSIONS
(INCHES)
0.5620 - 0.5626
0.7485 - 0.7495
1.059 - 1.080
1.9348 - 1.9385
1.9365 - 1.9385
1.3115 - 1.3125
2.267 - 2.282
1.938 - 1.940
new bearing in until it is 0.03 thousandths of an inch
below inner surface.
Any studs found to be damaged or loose must be
replaced in accordance with the instructions in Section
5-22. See Figure 13-2," Starter Adapter Stud Setting
Heights," for proper stud setting heights.
Section 5-19,"Application Of Accelagold," applies to
all aluminum alloy castings, sheet metal and tubing.
13-6 OPTIONAL STARTER
AND STARTER ADAPTER
SUB-ASSEMBLY TSI0-360-RB
1. See Figure 6-8, "Optional Starter And Starter
Adapter TSI0-360-RB." Press new bearing (9)
onto worm shaft and gear assembly (8). Press
bearing until seated against flange. Install new
retaining ring (10). Coat the worm gear teeth with
clean molyshield grease. Insert assembly into
adapter housing and install new retaining ring
(11). Insure that retaining rings are properly
seated.
2. Install a new roller bearing (12) in worm wheel
gear (13). Install new clutch spring (14) on worm
wheel (13). Turn spring so it tends to unwind until
offset end drops into the worm wheel gear land.
Position spring on gear so screw notch is aligned
with screw hole in gear web. Install new tab
washer (15) and screw (16). Torque screw (16) to
75.0-85.0 inch pounds torque, and bend tab up
against screw head.
3. Lubricate spring and shaft gear liberally with
clean 50 weight aviation engine oil that conforms
with MIL-C-6529 Type ll specification. Press
worm wheel and spring assembly onto shaft gear
(17). Insert shaft gear and worm wheel assembly
into adapter. Make sure worm wheel and worm
gear teeth are aligned.
4. Apply TCM Gasket Maker to the outside
diameter of new uncoated oil seals. Using an
arbor press install new bushing (20) and oil seal
(21) in scavenge pump body (19). Clean scavenge
pump body removing any debris. Lubricate
bushing and oil seal with clean 50 weight aviation
engine oil. Lubricate new or serviceable scavenge
pump gear shafts, ends and teeth (25, 27) with
clean molyshield grease. Lubricate the scavenge
pump housing and cover gear contact areas using
clean molyshield grease. Install scavenge gears
(25, 27) in scavenge pump body (19). Install new
or serviceable scavenge pump cover (29) on
scavenge pump body (19) and secure using
washers (32) and screws (33). Torque screws (33)
to 75-85 inch pounds and lockwire in accordance
with Section 4-2. Insure that gears (25, 27) rotate
freely.
5. Center scavenge pump gear (27) inside scavenge
pump body (19). Using new o-ring (18), install
scavenge pump body (19) on starter adapter
housing and insure that shaftgear (17) has
properly aligned with scavenge pump gear (27).
Install lifting eye (51) and secure using washers
(35), new lock washer (36) and nut (37). Snug but
do not torque nut (37) at this time.
6. Using new gasket (38), install cover (39) and
secure using washers (40), new lock washers (41)
and nuts (42). Torque nuts (42) to 75-85 inch
pounds torque.
7. Store the starter and starter adapter in a clean
protected area until final engine assembly.
13-8
STARTER AND
STARTER ADAPTER
SUB-ASSEMBLY LTSI0-360-RB
1. See Figure 6-9, "Starter And Starter Adapter
LTSI0-360-RB." Press new bearing (13) onto
worm shaft (8). Press bearing until seated against
flange. Using new woodruff key (9) install gear
(10) on worm shaft (8). Install bushing (11) and
new pin (12) on worm shaft (8). Coat the worm
gear teeth with clean molyshield grease. Insert
assembly into adapter housing and install new
retaining ring (14). Insure that retaining ring is
properly seated.
2. Install a new roller bearing (15) in worm wheel
gear (16). Install new clutch spring (17) on worm
wheel (16). Turn spring so it tends to unwind until
offset end drops into the worm wheel gear land.
Position spring on gear so screw notch is aligned
with screw hole in gear web. Install new tab
washer (18) and screw (19). Torque screw (19) to
75.0-85.0 inch pounds torque, and bend tab up
against screw head.
3. Lubricate spring and shaft gear liberally with
clean 50 weight aviation engine oil. Press worm
wheel and spring assembly onto shaft gear (20).
Insert shaft gear and worm wheel assembly into
adapter. Make sure worm wheel and worm gear
teeth are aligned.
4. Apply TCM Gasket Maker to the outside
diameter of new uncoated oil seals. Using an
arbor press install new bushing (23) and oil seal
(24) in scavenge pump body (22). Clean scavenge
pump body removing any debris. Lubricate
bushing and oil seal with clean 50 weight aviation
engine oil. Lubricate new or serviceable scavenge
pump gear shafts, ends and teeth (27, 29) with
clean molyshield grease. Lubricate the scavenge
pump housing and cover gear contact areas using
clean molyshield grease. Install scavenge gears
(27, 29) in scavenge pump body (22). Install new
or serviceable scavenge pump cover (31) on
scavenge pump body (22) and secure using
washers (34) and screws (35). orque screws (35)
to 75-85 inch pounds and lockwire in accordance
with Section 4-2. Insure that gears (27, 29) rotate
freely.
13-9
Chapter 13
5. Center scavenge pump gear (29) inside scavenge
pump body (22). Using new o-ring (21), install
scavenge pump body (22) on starter adapter
housing and insure that shaftgear (20) has
properly aligned with scavenge pump gear (29).
Install lifting eye (55) and secure using washers
(50, 37), new lock washer (38) and nut (39). Snug
but do not torque nut (39) at this time.
13-10
6. Using new gasket (40), install cover (41) and
secure using washers (42), new lock washers (43)
and nuts (44). Torque nuts (44) to 75-85 inch
pounds torque.
7. Store the starter and starter adapter in a clean
protected area until final engine assembly.
Chapter 14
CHAPTER 14
ACCESSORY CASE
SECTION
14-1
14-2
14-3
14-4
14-5
14-6
PAGE
Accessory Case Disassembly........................................ 14-2
Oil Pump Removal ........................................................ 14-2
Accessory Case Cleaning.............................................. 14-2
Accessory Case and Associated Parts Inspection......... 14-2
Accessory Case Repair and Replacement..................... 14-6
Accessory Case Sub-Assembly .................................... 14-6
FIGURE
14-4
14-5
PAGE
Accessory Case Stud Setting Heights ........................... 14-4
Oil Pressure Relief Valve Fits and Limits .................... 14-5
14-1
Chapter 14
14-1 ACCESSORY CASE
DISASSEMBLY (See Figures 6-10
and 6-10A.)
1. All gaskets, lock washers and self-locking nuts
removed from the accessory case must be
replaced 100% at overhaul. Cleaning these parts
is not required.
1. Remove attaching hardware (29, 30, 31). Remove
oil filter and oil filter adapter (25, 28) from
accessory case (2). Remove fitting (27) from oil
filter adapter ((25). Cut and remove safety wire
(6) and separate oil filter (28) from oil filter
adapter (25). Remove o-ring (24) from oil filter
adapter ((25) and discard. Discard oil filter (28)
and lock washers (29). Remove gasket (23) from
accessory case (2) and discard.
2. The accessory case oil passages must be flushed
with mineral spirit solvent and inspected with a
flashlight.
2. Cut and remove safety wire (6). Loosen and
remove oil pressure relief valve cap (11),
adjusting screw (12), washer (13, Nut (14), gasket
(10), spring (9) and plunger (8). Discard gasket
(10) and spring (9).
3. Cut and remove safety wire (6). Loosen and
remove screen (22) and gasket (21). Discard
gasket (22).
4. Cut and remove safety wire (6). Loosen and
remove plugs (5) and gaskets (4). Discard gaskets
(4).
5. Remove attaching hardware (18, 19, 20). Remove
cover and gasket (17, 16). Discard gasket (16).
14-2 OIL PUMP REMOVAL
(See Figures 6-10, 6-10A and 6-11.)
1. See Figures (6-10 and 6-10A). Remove Nut (15)
from oil pump drive gear. See Figure (6-11).
Remove oil pump drive gear (8). Bend tabs of tab
washers (6) down. Remove bolts (7). Discard tab
washers (6).
2. Separate cover (5) from oil pump cavity and
remove oil pump gears (2 and 4).
14-3 ACCESSORY CASE
CLEANING
The accessory case must be cleaned in accordance
with the instructions in Section 5-7, "General
Cleaning," and the following special instructions:
14-2
3. If the accessory case casting is immersed in an
alkaline bath, it must be sprayed with steam to
remove all traces of alkaline. After the casting
dries, inspect it for any alkaline residues. If
necessary, re-spray with steam to remove
remaining residue. The accessory case and all oil
passages must be thoroughly flushed with mineral
spirit solvent after any alkaline cleaning process
has been used.
CAUTION…
Alkaline cleaning solutions will cause corrosion to
metals if not completely removed.
14-4 ACCESSORY CASE AND
ASSOCIATED PARTS
INSPECTION
VISUAL INSPECTION
The accessory case and associated components must
be visually inspected in accordance with instructions
in Section 5-8, "Visual Inspection," and the following
special instructions:
1. Visually inspect the inside and outside of the
accessory case for cracks. Pay particular attention
to areas on and adjacent to accessory mount
flanges, case flange, oil pump cavity and oil
pressure relief valve boss. Look for scoring in the
oil pump cavity and shaft bores. Visually inspect
all machined surfaces for nicks and roughness.
Inspect the accessory case mounting flange on a
surface plate for warpage. Inspect the oil pump
driven gear shaft for security and wear. Accessory
cases with loose or worn oil pump driven gear
shafts must be replaced.
Chapter 14
2. Inspect all oil passages for restrictions. Accessory
cases with restricted oil pump housing oil
passages that cannot be cleared by solvent action
must be discarded. Inspect the oil pump housing
gear shaft for scoring. Housings with scored gear
shafts must be discarded.
3. Inspect the oil pressure relief valve seat for any
indications of wear. Oil pressure relief valve seats
with indications of wear must be refaced.
CAUTION…
Reface pressure relief valve seat using light finger
pressure when turning refacing tool.
CAUTION…
Thoroughly clean oil pressure relief valve cavity after
refacing procedure.
4. Visually inspect all pipe plugs for stripped or
distorted threads and damaged wrench flats. Pipe
plugs exhibiting damaged threads or wrench flats
must be discarded.
5. Visually inspect the tach drive adapter mounting
flange for cracks, nicks and scratches on
machined surfaces. Inspect adapter for distorted
or stripped threads.
6. Visually inspect all accessory case helical coils,
threaded holes and studs for stripped or distorted
threads. Inspect studs for corrosion, rusting,
pitting, incomplete threads and looseness. Check
all studs with a tool maker's square for alignment.
All studs must have their setting heights checked
for indications of backing out. See the following
for accessory case stud setting heights.
14-3
Chapter 14
ITEM
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
LOCATION
Oil Filler Neck
Helical Coil
Helical Coil
Stud, Alternator Mount
Stud,, Oil Filter Adapter
Stud,, Magneto Mount
Plug
Stud, Tach Drive Mount
Plug
THREAD
SIZE
---5/16 - 18
5/16 - 18
5/16 -18 x 5/16-24
5/16 -18 x 5/16-24
5/16 -18 x 5/16-24
---1/4 - 20 x 1/4 - 28
----
SETTING
HEIGHT
---------.81
1.00
.72
---.59
----
FIGURE 14-1. ACCESSORY CASE STUD SETTING HEIGHTS
14-4
QTY.
1
2
1
3
3
3
1
3
2
Chapter 14
FLUORESCENT PENETRANT INSPECTION
The accessory case must be fluorescent penetrant
inspected by a certified technician in accordance with
the instructions in Section 5-12, "Fluorescent
Penetrant Inspection." Accessory cases that exhibit
cracks must be discarded or repaired in accordance
with the instructions in Section 14-5.
DIMENSIONAL INSPECTION
The following new parts limits must be used for
dimensional inspection. Components that do not meet
the following specifications must be discarded.
All components must be thoroughly cleaned and air
dried prior to dimensional inspection.
FIGURE 14-2. OIL PRESSURE RELIEF VALVE FITS AND LIMITS
REF.
NO.
1.
DESCRIPTION
Oil pressure relief valve seat ............................................................ Depth:
NEW PARTS
MIN.
MAX.
1.19
1.29
14-5
Chapter 14
14-5
ACCESSORY CASE
REPAIR AND REPLACEMENT
1. The accessory case must be replaced if worn
beyond new parts limits or fails to meet the
inspection criteria in Section 14-4 unless repair is
possible with the following instructions.
2. If the accessory case is cracked, warped, oil pump
gear shaft bores or oil pump gear chambers are
enlarged or scored the accessory case must be
replaced. Accessory cases with loose or worn oil
pump driven gear shafts must be replaced.
3. Reface worn or damaged oil pressure relief valve
seats as follows. Using an 8048 Oil Pressure
Relief Spot Facer reface the pressure relief valve
seat in the accessory case oil pressure relief valve
cavity. See Chapter 2, "Tools, Equipment
Sealants and Lubricants." Do not exceed the
specified limit in oil pressure relief valve fits and
limits. If the oil pressure relief valve seat is worn
beyond the specified limit and cannot be refaced
the accessory case must be discarded.
4. Accessory cases with oil pump housing gear
shafts that exceed the specifications in new parts
dimensions or that are loose must be discarded.
The oil pump housing driven gear shaft is pressed
into the accessory case oil pump housing and is
not field replaceable.
5. Accessory cases with nicks or gouges on the oil
pump housing flange must be discarded unless the
parting surface can be lapped smooth and made
perfectly flat without exceeding the specifications
in new parts dimensions.
6. Damaged or loose studs may be replaced in
accordance with instructions in Section 5-22. See
Figure 14-1,"Accessory Case Stud Setting
Heights," for location and height dimensions.
7. Section 5-19,"Application Of Accelagold,"
applies to all aluminum alloy castings, sheet metal
and tubing.
NEW PARTS DIMENSIONS
PART NAME
Oil pump housing and
shaft assembly
FEATURE
Driven gear shaft outside diameter
Upper oil pump gear shaft bore diameter
Oil pump cavity, Gear chamber depth
14-6 ACCESSORY CASE
SUBASSEMBLY (See Figure
14-1.)
NOTE…
All accessory case components must be clean and free
of debris before assembly.
1. See Figures 6-10 or 6-10A as applicable. Install a
new gasket (10) on cap (11). Coat cap (11)
threads with anti-seize lubricant TCM P/N
646943. See Chapter 2 for anti-seize lubricant
supplier. Install adjusting screw (12) into cap (11)
and screw in about half way. Install washer (13)
14-6
NEW DIMENSION
(INCH)
.3735 - .3740
.719 - .720
.7450 - .7470
and nut (14) on protruding end of adjusting screw
(12) but do not torque at this time. Assemble
pressure relief valve cap (11) plunger (8), new
spring (9) and slide into accessory case relief
valve opening. Torque relief valve cap to 190-210
inch pounds. Safety wire cap (11) in accordance
with Section 4-2, "Lockwire Procedure."
2. The oil pump will be assembled in Chapter 15.
3. Store accessory case and components in a clean
protected area until lubrication system
sub-assembly.
Chapter 15
CHAPTER 15
LUBRICATION SYSTEM
SECTION
15-1
15-2
15-3
15-4
15-6
PAGE
Oil Cooler Disassembly.................................................... 15-2
Lubrication System Component Cleaning ....................... 15-2
Lubrication System Component Inspection ..................... 15-3
Lubrication System Component Repair
and Replacement............................................................... 15-5
Lubrication System Sub- Assembly................................. 15-7
FIGURE
15-1
15-2
PAGE
Lubrication System Fits And Limits ................................ 15-5
Oil Filter Adapter Stud Setting Height............................. 15-6
15-1
Chapter 15
15-1
OIL COOLER
DISASSEMBLY (See Figure 6-12)
1. Cut and remove lock wire. Remove oil
temperature control valve (7) and gasket (6) from
oil cooler adapter. Discard gasket (6).
2. Cut and remove lock wire. Remove plug (12) and
gasket (11). Discard gasket (11).
15-2 LUBRICATION SYSTEM
COMPONENT CLEANING
All lubrication system components and associated
hardware must be cleaned in accordance with the
instructions in Section 5-7, "General Cleaning," and
the following special instructions:
1. All oil pressure springs, gaskets, packings,
o-rings, seals, lock washers, tab washers and selflocking nuts removed from the lubrication system
components must be replaced 100% at overhaul.
Cleaning these parts is not required.
2. There are no structural repairs allowed to the oil
cooler assembly. Oil coolers with structural
damage, bent, broken or cracked cooling fins
must be replaced with a new or serviceable oil
cooler. Weld repairs to the mounting flange
brackets may be accomplished by a certified
repair facility.
3. Clean the oil sump assembly using mineral spirit
solvent.
4. If the oil sump is immersed in an alkaline bath,
when removed, it must be sprayed with steam
removing all traces of alkaline. After the sump
dries, inspect it for any alkaline residues and if
necessary re-spray with steam to remove. The
sump exterior, cavities and all oil passages must
be thoroughly flushed with mineral spirit solvent
after any alkaline cleaning process has been used.
15-2
CAUTION…
Alkaline cleaning solutions will cause corrosion to
metals if not completely removed.
5. Clean the oil filter adapter assembly using mineral
spirit solvent. All oil passages must be clear and
free flowing.
6. Clean the oil suction tube assembly using mineral
spirit solvent. All oil passages must be clear and
free flowing.
7. Clean gears that have bushings using mineral
spirit solvent and a brass wire brush. Gears with
bushings must not be cleaned using alkaline
solutions. Gears that do not have bushings can be
cleaned using mineral spirit solvent or by
immersion in a alkaline stripping bath if mineral
spirit solvent is not effective. After cleaning with
alkaline solution the gears must be sprayed with
steam removing all traces of alkaline. After steam
rinsing the gears must be thoroughly flushed with
mineral spirit solvent.
CAUTION…
Alkaline cleaning solutions will cause corrosion to
metals if not completely removed.
WARNING
Do not pressure blast gears with an abrasive
media. Blasting will remove surface
hardening.
Chapter 15
15-3 LUBRICATION SYSTEM
INSPECTION
VISUAL INSPECTION
The lubrication system components must be visually
inspected in accordance with instructions in Section
5-8, "Visual Inspection." Special attention must be
given to the following components and areas:
1. Inspect oil pump gear teeth for signs of
overheating and excessive wear. Normal wear
produces a fine polish on the tooth thrust faces.
Gears that have alteration of the tooth profiles,
score marks, burning or pitting must be discarded.
Check the oil pump drive gear shaft and shaft
threads for wear and damage. Discard drive gears
with any of these indications. See Figure 8-1,
“Gear Tooth Inspection,” for acceptable and
unacceptable gear tooth wear.
2. Visually inspect the oil sump bolt holes for
cracks. Inspect mounting surface for scratches,
warpage and cracks. Warped, cracked or leaking
oil sumps must be discarded. Inspect the oil drain
plug boss and drain plug for damaged threads.
Inspect the drain plug for damaged wrench flats.
Discard oil drain plugs with damaged threads.
3. Using a flashlight and a 10X magnifying glass
inspect all areas of the oil filter adapter for cracks
and indications of cracks. Discard any oil filter
adapter with cracks or crack indications. Inspect
the oil filter adapter flange for warpage. Filter
adapters exhibiting warpage must be discarded.
4. Visually inspect the oil suction tube assembly for
dents, cracks and distorted or restricted openings.
Oil suction tubes exhibiting dents, cracks or
distorted openings must be discarded.
FLUORESCENT PENETRANT INSPECTION
Aluminum alloy components such as the oil filter
adapter and oil sump must be fluorescent penetrant
inspected by a certified technician in accordance with
Section 5-12, "Fluorescent Penetrant Inspection."
Adapters or sumps exhibiting cracks must be
discarded.
MAGNETIC PARTICLE INSPECTION
Oil pump gears must be magnetic particle inspected
by a certified technician in accordance with the
instructions in Section 5-9, "Magnetic Particle
Inspection." Oil pump gears exhibiting cracks must
be discarded.
15-3
Chapter 15
DIMENSIONAL INSPECTION
The following new parts limits must be used for dimensional inspection. Components that do not meet the
following specifications must be discarded.
All components must be thoroughly cleaned and air dried prior to dimensional inspection.
LUBRICATION SYSTEM FITS AND LIMITS
REF.
NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
DESCRIPTION
Oil pump gears in housing........................................................ End Clearance:
Oil pump gears in housing.................................................................Diameter:
Oil pump gear shafts in housing ........................................................Diameter:
Oil pump gear shafts in cover............................................................Diameter:
Oil pump driven gear on shaft ...........................................................Diameter:
Oil pump driver gear to driven gear ..................................................Backlash:
Driver gear shaft in oil pump drive gear............................................Diameter:
Oil pump driver gear to camshaft gear ..............................................Backlash:
Oil pressure relief valve spring (compressed to 1.58 inches) ..................Load:
Oil temperature control valve 0.090 inch minimum
travel at...................................................................................Oil Temperature:
Oil temperature control valve must be fully closed ..............Oil Temperature:
Oil temperature control valve must crack open at 180°F......................... PSI:
NEW PARTS
MIN. MAX.
0.001
0.004
0.0015L
0.004L
0.0005L
0.002L
0.0005L
0.002L
0.0005L
0.002L
0.014
0.0218
0.0005L
0.002L
0.010
0.014
14.5-15.5 Lbs.
FIGURE 15-1. LUBRICATION SYSTEM FITS AND LIMITS
15-4
120°F-170°F
168°F-172°F
18 Pounds
Chapter 15
NEW PARTS DIMENSIONS
PART NAME
Oil Pump Drive Gear
Oil Pump Gears
Oil pump cover
FEATURE
Shaft outside diameter
Upper oil pump gear inside diameter
Upper oil pump gear outside diameter
Driven Gear Inside Diameter
Upper oil pump gear shaft bore diameter
15-4 LUBRICATION SYSTEM
COMPONENT REPAIR AND
REPLACEMENT
Any lubrication system component worn beyond new
parts limits or failing to meet the inspection criteria in
Section 15-3 must be replaced unless repair is
possible with the following instructions:
1. Oil pump covers with scored gear contact surfaces
must be discarded,
NEW DIMENSION
(INCH)
.3735 - .3740
.3745 - .3755
.7180 - .7185
.3745 - .3755
.719 - .720
2. Oil filter adapters exhibiting cracks must be
discarded.
3. Oil pump drive gears worn beyond specifications
must be discarded. Oil pump driven gears with
bushings that are worn beyond specifications
must be discarded. See Section 15-3, "New Parts
Dimensions."
4. Oil sumps that leak or that are cracked must be
discarded.
5. Section 5-19, "Application of Accelagold,"
applies to all aluminum alloy castings, sheet metal
and tubing.
15-5
Chapter 15
FIGURE 15-2. OIL FILTER ADAPTER STUD SETTING HEIGHT
ITEM
NO
Stud
LOCATION
Oil Filter to Adapter
THREAD
SIZE
3/4 - 16 X 13/16 -16
7. Install new stud in accordance with the following
procedure:
a. Remove old stud and inspect the threads in
the adapter housing for damage. Replace the
adapter housing if any thread damage is
evident.
b. Clean the adapter housing threads thoroughly
to remove any remaining thread adhesive and
oil.
c. Install the applicable new stud (P/N 653489)
and confirm that the incomplete thread on the
stud stops at the first thread in the adapter
housing and does not continue into the
housing below the minimum 0.500 inch
extension. See Figure 15-10, "Oil Filter
Adapter Stud Inspection." Replace the
adapter housing if the extension is less than
the specified 0.500 inch minimum.
.
15-6
SETTING
HEIGHT
500 - .700
QTY.
1
d. After extension height inspection, remove the
stud from the adapter. Clean the threads of
the adapter housing and stud with Loctite
"Primer T" (TCM P/N 646944) and allow to
dry.
e. Apply a line of Loctite 271 (TCM P/N
646941) along the large threads (.8125-16
end) of the stud and install into the adapter
finger tight to 30 inch pounds torque. Check
for proper stud extension height in
accordance with Figure 15-10, "Oil Filter
Adapter Stud Inspection."
f.
Allow the parts to cure a minimum of 30
minutes prior to installation of the oil filter.
CAUTION…
Curing times may vary depending on ambient
temperature. Consult Loctite instructions
Chapter 15
15-6 LUBRICATION SYSTEM
SUB-ASSEMBLY
NOTE…
All lubrication system components must be clean and
free of debris before assembly.
NOTE…
Before assembly insure all parts listed in Section 5-6,
"100% Replacement Parts," have been replaced.
1. See Figure 14-3, "Oil Pump Assembly." Using
clean 50 weight aviation engine oil, coat oil pump
drive and driven gears (2, 4) liberally. See
Chapter 3 for lubricant suppliers. Install gears (2,
4) into accessory case oil pump cavity. Install oil
pump cover (5) and secure with attaching
hardware (6, 7). Torque bolts (7) to 75-85 inch
pounds. Safety bolts (7) by bending tabs of tab
lock washers (6) up against bolt heads in
accordance with Section 4-3, "Tab Washer
Procedures." Check oil pump gears for freedom
of rotation.
NOTE…
Before installing oil temperature control valve and
plug in oil cooler adapter, insure they are clean and
free of any debris.
2. See Figure 15-1, "Oil Cooler.” Using new copper
gasket (11) install plug (12) in oil cooler adapter.
Torque plug to 190-210 inch pounds. Using new
o-ring (6) install oil temperature control valve (7)
in oil cooler adapter. Torque oil temperature
control valve (7) to 440 - 460 inch pounds. Safety
wire oil temperature control valve (7) and plug
(12) in accordance with Section 4-2, "Lockwire
Procedure."
WARNING
Never use teflon tape on lubrication system
fittings.
3. See Figure 15-2, Apply a small amount of Loctite
Pipe Sealant 592 to oil suction tube threads.
Install oil suction tube assembly (9) into oil sump
(2). Torque the oil suction tube to 310-350 inch
pounds. Using a new gasket (8), install plug (7)
into oil sump (2). Torque plug (7) to 185-215 inch
pounds and safety wire in accordance with
Section 4-2, "Lockwire Procedure."
4. The accessory case, oil filter adapter, oil filter
assembly and oil sump will be installed during
final engine assembly. Cover components and
store in a clean protected area until final
assembly.
15-7
Chapter 15
INTENTIONALLY
LEFT
BLANK
15-8
Chapter 16
CHAPTER 16
CYLINDERS AND PISTONS
SECTION
16-1
16-2
16-3
16-4
16-5
16-6
PAGE
Cylinder and Associated Parts Disassembly ......................... 16-2
Precleaning Inspection........................................................... 16-2
Cylinder and Associated Parts Cleaning ............................... 16-2
Cylinder and Associated Parts Inspection ............................. 16-3
Cylinder Assembly Repair and Replacement........................ 16-14
Cylinder and Piston Sub-Assembly....................................... 16-27
FIGURE
16-1
16-2
16-3
16-4
16-5
16-6
16-7
16-8
16-9
16-10
16-11
16-12
16-13
16-14
16-15
16-16
16-17
16-18
PAGE
Cylinder Inspection................................................................ 16-5
Cylinder Stud Setting Heights ............................................... 16-6
Cylinder Fits and Limits ....................................................... 16-11
Cylinder Dimensions ............................................................ 16-12
Intake Valve Seat Refacing ................................................... 16-18
Exhaust Valve Seat Refacing ................................................ 16-18
Prying Spark Plug Helical Coil away from Cylinder............ 16-20
Removing Spark Plug Hole Helical Insert ............................ 16-20
Installing Spark Plug Hole Helical Insert.............................. 16-20
Expanding Spark Plug Hole Helical Insert ........................... 16-20
Rocker Arm Bushing Replacement....................................... 16-22
Rocker Arm To Rotocoil Clearance ...................................... 16-23
Intake Valve Refacing ........................................................... 16-24
Valve Gauge Line Inspection Fixture.................................... 16-26
Cylinder and Piston Position Number ................................... 16-27
Valve and Spring Installation ................................................ 16-27
Installing Baffle...................................................................... 16-28
Securing Baffle ...................................................................... 16-28
16-1
Chapter 16
1. See Figure 6-15, "Cylinder And Piston
Assembly." Place the cylinder to be disassembled
on a cylindrical block of wood anchored to a
work bench.
2. Discolored or burnt paint may indicate piston and
piston pin scoring of the cylinder bore caused by
overheating. Scored cylinder barrel bores and
barrel bores that have been overheated must be
discarded and replaced. Do not attempt to remove
overheating damage by grinding cylinder bore to
the next allowable oversize. Cylinder barrel
overheating can destroy the strength of the
material.
2. Using a valve spring compression tool, carefully
compress valve springs (do not cock the rotocoil
and score the valve stem.) Remove retaining keys
(17) with a retrieval magnet and discard. Remove
and discard rotocoil (16), outer springs (14) and
inner springs (13). Remove inner retainers (15).
Remove and discard intake valve guide seal (5).
Hold the valve stems while lifting the cylinder
from its support and place the cylinder on its side.
Remove any nicks on the valve stems using an
emery stone or cloth before removing valves.
Discard exhaust valves (11).
3. If the cylinder deck stud nuts have been properly
torqued during operation, when the cylinder is
removed, a contact pattern can be observed
around the stud holes and between the stud holes
of the cylinder contact flange. If the engine has
operated with loose cylinder deck studs fretting
and galling will be present in this area. Inspect the
cylinder to crankcase mating flange for fretting
and galling indicating cylinder movement. If
movement has occurred, replace all cylinder deck
studs on the corresponding cylinder deck of the
crankcase.
3. Remove the cylinder exhaust flange studs and
rocker shaft hold down studs using a stud
remover. Discard studs.
16-3
CYLINDER AND
ASSOCIATED PARTS
CLEANING
16-1 CYLINDER AND
ASSOCIATED PARTS
DISASSEMBLY
4. Support the rocker arm on a ring that will allow
the old bushings to pass through. Press the worn
bushings out using the proper size tool. Discard
the bushings.
5. Disassemble the remaining cylinders and rocker
arms using the above procedure.
16-2 PRECLEANING
INSPECTION
1. Prior to cleaning the cylinder assemblies, inspect
them for any signs of head to barrel leakage,
leaking oil, fuel, exhaust or combustion residue
and any condition that could indicate loss of
integrity of the cylinder assembly or the cylinder
head to barrel junction. Inspect the cylinder barrel
fins and fin tips for rust pitting and damage in the
power stroke stress areas. Discard any cylinder
with the above described conditions. Inspect the
remainder of the cylinder barrel, barrel fins, fin
tips and cylinder base flange for rust pitting and
damage that cannot be repaired in accordance
with the instructions in Section 15-5. Discard all
cylinders which cannot be repaired.
16-2
WARNING
Do not use sand, glass shot or metal grit for
cleaning.
1. Clean cylinder assemblies and associated parts in
accordance with the instructions in Section 5-7,
"General Cleaning," and the following special
instructions:
2. Precautions applicable to both aluminum and steel
must be exercised in cleaning the cylinder
assembly. Remove oil and loose material with a
mild alkaline cleaner by spraying or brushing.
Remove all traces of the alkaline by spraying with
steam. After the cylinder dries, inspect it for any
alkaline residues and, if necessary, respray with
steam to remove.
CAUTION…
Alkaline cleaning solutions will corrode metals if not
completely removed.
Chapter 16
3. Remove all paint, varnish and carbon from the
cylinder assembly to allow complete inspection.
The cylinder assembly may be dry blasted. Use
blasting techniques to remove hard carbon
deposits with the lowest air pressure that will
produce the desired results. All machine surfaces,
the cylinder mount flange nut seats, cylinder
barrel wall, small holes and finished surfaces must
be protected from the blast by seals and covers.
Suitable types of materials for dry blasting are
plastic pellets and processed natural materials
such as wheat grains and crushed fruit pits or
shells.
4. After any blasting process, blow off all dust with
dry compressed air and insure that no blasting
material has lodged in crevices, recesses or holes.
Clean the cylinder with hot, soapy water and a
stiff bristled scrub brush to remove all blasting
material from the cylinder. After washing, remove
all soap residue by thoroughly rinsing with hot
water. Dry the cylinder completely and coat all
bare steel surfaces thoroughly with clean 50
weight aviation engine oil. Failure to clean and
protect the cylinder in this manner could result in
cylinder bore damage from rust and
contamination.
5. Degrease the intake valves with mineral spirits.
Remove all carbon, varnish and gum from the
intake valves using a carbon solvent or by dry
blasting.
Use blasting techniques to remove hard carbon
deposits with the lowest air pressure that will
produce the desired results. Suitable types of
materials for dry blasting are plastic pellets and
processed natural materials such as wheat grains
and crushed fruit pits or shells.
After dry blasting, clean with mineral spirits and
air dry.
Clean all pushrods and rocker arms using mineral
spirits. Using a small squirt bottle, insure all
pushrod and rocker arm oil passages are open by
flushing with mineral spirits. Discard any pushrod
or rocker arm that has obstructed oil passages that
cannot be cleared by solvent action. DO NOT
CLEAN PUSHRODS AND ROCKER ARMS
BY BLASTING.
Dry all components completely and thoroughly
coat with clean 50 weight aviation engine oil.
6. Clean all cylinder baffles and associated hardware
using mineral spirits.
16-4
CYLINDER AND
ASSOCIATED PARTS
INSPECTION
VISUAL INSPECTION
Visually inspect the cylinder assembly and associated
components in accordance with the instructions in
Section 5-8, "Visual Inspection," and the following
special instructions:
CYLINDER BARREL
1. Power Stroke Stress Area of the cylinder barrelVisual inspection must include a detailed external
inspection of the areas of the cylinder barrel
which experience the highest operational stresses
from the piston power stroke. These areas are the
12 o'clock area of the first six fins below the head
on one side of the engine, and the 6 o'clock area
on the other side as described in Figure 16-1.
2. Inspect the cylinder barrel areas including the
cylinder barrel fins and the areas between and
adjacent to the fins for cracks, sharp indentations,
rust, pitting, broken or bent fins, (including bent
fins that have been straightened) and chafing
damage that alter the original barrel surface
contour, fin tip contour or reduce the thickness of
the barrel fins. Cylinder barrels with any of the
above conditions must be discarded.
3. Remaining Cylinder Barrel Areas -. Thoroughly
inspect the remaining cylinder barrel areas
including the cylinder barrel fins and the areas
between and adjacent to the fins for cracks, sharp
indentations, chafing damage, rust and pitting.
Inspect the cylinder barrel flange and flange
radius for rust and pitting. Cylinder barrels with
bent fins in this area may continue in use,
provided that the fin is not bent more than
one-half of the distance to the next fin, that no
attempt is made to straighten the bent fin and
there are no cracks or evidence of cracks. Minor
fin tip damage repair may be accomplished on fin
tips in this area as described in Section 16-5.
OTHERWISE CYLINDER REPLACEMENT IS
REQUIRED.
16-3
Chapter 16
WARNING
Corrosion pits reduce wall thickness and will
cause stress concentrations and subsequent
fracture. Damage or removal of external
barrel material that results in a reduction of
the barrel wall thickness is strictly prohibited
regardless of location and requires cylinder
replacement.
4. Inspect the entire cylinder barrel for electrical arc
pitting or weld repairs. Electrical arc pitting or
weld repairs of any surface on the cylinder barrel
is strictly prohibited. if such conditions are
present discard cylinder.
5. Inspect the cylinder bore for overheating or high
temperature operation, detonation, piston scoring,
or piston pin damage to the cylinder bore. Discard
all such cylinders.
16-4
CYLINDER HEAD
1. Inspect the external surfaces of the cylinder head
including the exhaust port cylinder head fins, in
between the fins, exhaust ports, top and bottom
spark plug bosses and fuel nozzle boss for cracks
or indications of cracks. Discard any cylinder
with cracks or indications of cracks.
2. Minor cooling fin cracks that do not extend into
the cylinder head structure may be repaired in
accordance with Section 16-5
3. Heat checks in the exhaust port that are 1/8” inch
in length or less may continue in service.
Chapter 16
FIGURE 16-1. CYLINDER INSPECTION
16-5
Chapter 16
FIGURE 16-2. CYLINDER STUD SETTING HEIGHTS
16-6
Chapter 16
WARNING
Welding of the cylinder head structure can
destroy the assembly preloads and casting
strength resulting in cylinder assembly failure.
4. Inspect the intake flange studs for damaged,
distorted or stripped threads. Inspect studs for
corrosion, rusting, pitting, incomplete threads and
security. Replace studs with any of these
indications.
5. Inspect the cylinder exhaust flange studs and
rocker shaft hold down stud holes for distorted
and stripped threads. Repair damaged, distorted
and stripped threads in accordance with Section
5-21.
6. Check all studs with a tool maker's square for
perpendicularity. Check all studs for security and
correct setting height. See Figure 16-2 for stud
setting heights.
7. Damage to threaded bores - Inspect rocker cover
flange screw holes for complete threads. Inspect
all helical coils for damage. The spark plug
helical coil outer ends must lie in the first full
thread of the tapped holes in which they are
installed. The helical coil teeth at the outer end of
the helical coil must not be visible. Repair
threaded bores in accordance with Section 5-21
and Figure 16-2.
INTAKE VALVES
Visually inspect the intake valves using a 10X
magnifying glass. Inspect the intake valve stems for
scoring, damage in valve retainer grooves and spalling
on stem tips. Place the valve head on a one inch wide
precision parallel bar and inspect for distortion with a
.001" feeler stock. Discard valves that are damaged,
distorted, cracked, burned, pitted or rusted. Valve
faces may be machined to the dimensions specified in
Figure 16-13, "Intake Valve Refacing."
ROCKER ARMS
Visually inspect all rocker arm foot contact areas for
wear, galling, spalling, scoring or grooves. Inspect
rocker arm ball seats for smoothness. Discard rocker
arms with any signs of wear, galling, spalling, scoring
or grooves. Inspect the thrust surfaces of the rocker
shaft bore for displaced metal, galling and spalling.
Discard all rocker arms with these conditions. Inspect
for, and discard any rocker arm that has peeling
copper plating. Inspect for and discard rocker arms
with loose or missing oil passage rivets. Inspect oil
passages for obstruction. Use an oil squirt bottle and
clean 50 weight aviation engine oil to check oil
passages for free flow. Rocker arms with blocked oil
passages that cannot be cleared by solvent action must
be discarded.
PUSHRODS
Visually inspect pushrod ball ends for smoothness,
cracks, galling, scoring, spalling and security. Inspect
pushrods for bending and warping. Discard pushrods
with any signs of wear, cracks, galling, scoring,
spalling, bending or warpage. Inspect pushrod oil
passages for obstructions. Use an oil squirt bottle and
clean 50 weight aviation engine oil to check oil
passages for free flow. Pushrods with blocked oil
passages that cannot be cleared by solvent action must
be discarded.
PUSHROD HOUSINGS
Visually inspect pushrod housings for cracks, dents,
bending and chafing damage. Discard cracked,
dented, bent or chafed pushrod housings. Discard any
pushrod housings with rust pitting and missing
cadmium plating.
CYLINDER BAFFLES
Visually inspect all cylinder baffles for cracks, loose
rivets, chafing damage and inspect anchor nuts for
security and damaged threads. Baffling that has
chafing damage caused by cylinder barrel fins
indicates that cylinder barrel fin damage may have
occurred. At this time inspect the corresponding
cylinder barrel fins for damage in accordance with the
cylinder assembly inspection procedure of this
section. Discard any baffles exhibiting cracks and
chafing damage. Replace damaged anchor nuts and
loose rivets.
16-7
Chapter 16
FLUORESCENT PENETRANT
INSPECTION
The cylinder assembly must be thoroughly cleaned
prior to fluorescent penetrant inspection. All oil and
preservative material must be removed.
The cylinder heads must be fluorescent penetrant
inspected by a certified technician in accordance with
Section 5-12, "Fluorescent Penetrant Inspection."
Cracks in the cylinder head structure are not
acceptable or repairable. Cylinder heads that exhibit
cracks or indications of cracks in the cylinder head
structure must be discarded. See Section 16-5 for
repair of cracked cylinder head fins.
MAGNETIC PARTICLE INSPECTION
The cylinder assembly must be thoroughly cleaned
prior to magnetic particle inspection. All oil and
preservative material must be removed.
16-8
The cylinder barrel must be magnetic particle
inspected by a certified technician in accordance with
Section 5-9, "Magnetic Particle Inspection." Inspect
the inner and outer surfaces of the cylinder barrel
using circular and longitudinal magnetization.
Cylinder barrels with cracks or crack indications are
not acceptable or repairable. Discard all such cylinder
assemblies.
The intake valves and rocker arms must be magnetic
particle inspected by a certified technician in
accordance with Section 5-9, "Magnetic Particle
Inspection." Inspect the intake valves and rocker arms
using circular and longitudinal magnetization. Intake
valves and rocker arms with cracks or crack
indications are not acceptable or repairable. Discard
all such valves and rocker arms.
Chapter 16
DIMENSIONAL INSPECTION
The following new parts limits must be used for dimensional inspection. Components that do not meet the
following specifications must be discarded.
All components must be thoroughly cleaned and air dried prior to dimensional inspection.
CYLINDER AND ASSOCIATED PARTS FITS AND LIMITS
Ref.
No.
Description
CYLINDERS
Cylinder bore (lower 4-1/4 inch of barrel) ..............................Diameter:
Cylinder bore choke (at 5.75 inch from open end of barrel) .......Taper:
Cylinder bore out-of-round..................................................................... :
Cylinder bore ..........................................................Allowable Oversize:
Cylinder bore surface (Nitrided Barrels)
Cross hatch....................................................................................Angle:
Finish (in micro inches) .......................................................................Ra:
6.
Cylinder barrel in crankcase ....................................................Diameter:
7.
Intake valve seat insert in cylinder head..................................Diameter:
8.
Intake valve guide in cylinder head.........................................Diameter:
9.
Exhaust valve guide in cylinder head......................................Diameter:
10.
Exhaust valve seat insert in cylinder head...............................Diameter:
11.
Intake valve seat............................................................................Width:
12.
Exhaust valve seat.........................................................................Width:
Exhaust valve seat-to-valve guide axis ........................................Angle:
Intake valve seat-to-valve guide axis ...........................................Angle:
ROCKER ARMS AND SHAFTS
13.
Rocker shaft in rocker arm bushing....................................... Diameter:
14.
Rocker arm bushing bore.........................................................Diameter:
Rocker arm bushing (inside)............................... Finish Bore Diameter:
15.
Rocker arm
Side Clearance:
16.
Rocker arm to Rotocoil..........................................................Clearance:
17.
Rocker arm grind ..........................................................................Width:
18.
Intake valve guide........................................................Inside Diameter:
Intake valve in guide ...............................................................Diameter:
19.
Exhaust valve guide.....................................................Inside Diameter:
Exhaust valve in guide.............................................................Diameter:
20.
Intake valve face (to stem axis) .................................................. Angle:
21.
Exhaust valve face (to stem axis) ............................................... Angle:
22.
Intake Valve ................................................................................ Length:
23.
Exhaust valve face-to-stem ........................................................ Length:
24.
Intake valve face-to-stem ........................................................... Runout:
25.
Exhaust valve face-to-stem (full indicator reading)................... Runout:
26.
Rocker arm foot to valve stem (dry valve gear lash) ............................. :
PISTONS, RINGS AND PINS
27.
Piston, moly coated (bottom of skirt) in cylinder ...................Diameter:
Piston, non moly coated (bottom of skirt) in cylinder ............Diameter:
28.
Top piston ring in groove ..............................................Side Clearance:
29.
Second piston ring in groove.........................................Side Clearance:,
Chapter
16
30.
Third piston ring in groove............................................Side Clearance:
1.
2.
3.
4.
5.
NEW PARTS
MIN.
MAX.
See Figure 16-4
See Figure 16-4
0.0000
0.001
See Figure 16-4
22° - 32°
—
30
50
0.0030L
0.0110L
0.0055T
0.0085T
0.0010T
0.0025T
0.0010T
0.0025T
0.0070T
0.0100T
See Figure 16-5
See Figure 16-6
44°30'
45° 00'
59° 30'
60° 00'
0.0010L
0.0040L
.716
.719
0.5945
0.5955
0.0020
0.0150
0.020
—
—
0.34
.3745
.3770
0.0010L
0.0040L
.3745
.3770
0.0025L
0.0057L
59°45'
60°15'
45°45’
46°15'
See Figure 16-13
Replace 100%
0.0000
0.0020
Replace 100%
0.060
0.200
0.004L
0.006L
0.0015
0.0015
0.003
0.009L
0.010L
0.008
0.008
0.005
16-9
Chapter 16
Ref.
No.
31.
32.
33.
34.
35.
36.
37.
NOTES:
Description
Fourth piston ring in groove..........................................Side Clearance:
Top ring gap at 1.00 ± .50 depth (in cylinder barrel)...................... Gap:
Second ring gap at 1.00 ± .50 depth (in cylinder barrel) ................ Gap:
Gap for second ring must be at least .006 larger than gap for top ring.
Third ring gap at 1.00 ± .50 depth (in cylinder barrel) .................. Gap:
Fourth ring gap at 1.00 ± .50 depth (in cylinder barrel) ................. Gap:
Piston pin in piston .................................................................Diameter:
Piston Pin .................................................................................Diameter:
T=Tight
0.019
0.015
0.0002L
0.9984
0.035
0.031
0.0006L
0.9986
L=Loose
CYLINDER DIMENSIONAL INSPECTION
1. Inspect cylinder bore dimensions in accordance
with Figure 16-4, "Cylinder Dimensions."
Cylinders bores that do not conform to the
standard size dimensions after honing must be
ground to the next oversize dimension.
2. Inspect the cylinder base flanges for flatness. If
cylinder base flange exceeds .001" out of flat, the
cylinder must be discarded.
3. Dimensionally inspect the cylinder exhaust flange
stud and rocker shaft hold down stud holes using
a thread gauge and determine the appropriate
oversize stud for replacement.
4. If intake flange studs have been removed for
replacement, dimensionally inspect the intake
flange stud hole(s) using a thread gauge and
determine the appropriate oversize stud for
replacement.
5. Dimensionally inspect the valve guides inside
diameter. Guide dimensions must be within
specifications the entire length of the guide.
Replace all valve guides that are worn beyond the
required specifications in accordance with the
procedures in Section 16-5.
16-10
NEW PARTS
MIN
MAX.
0.003
0.005
0.026
0.042
0.032
0.048
6. Visually inspect the valve seats for any indication
of burning, pitting, erosion or cracks. Determine
if the valve seat dimensions exceed the
specifications in Figures 16-5 and 16-6 . Any
valve seats that are burned, pitted eroded, cracked
or that do not conform with the specifications in
Figures 16-5 and 16-6 must be replaced.
INTAKE VALVE DIMENSIONAL
INSPECTION
1. Inspect the entire length of the valve stem outside
diameter with a micrometer. Discard valves with
stems less than 0.3730 diameter.
2. Using a micrometer inspect the valve head outside
diameter. Intake valves with heads smaller than
2.035 diameter must be discarded.
ROCKER ARM DIMENSIONAL
INSPECTION
1. Dimensionally inspect the rocker arm bushing
bore. The bushing bore must be .716 to .719 inch
diameter.
2. Dimensionally inspect the rocker arm thrust
width. The rocker arm width must be .937 to .940.
Chapter 16
FIGURE 16-3. CYLINDER FITS AND LIMITS
16-11
Chapter 16
NOTE…Dimensions shown are finished dimensions after honing.
FIGURE 16-4. CYLINDER DIMENSIONS
16-12
Chapter 16
NEW PARTS DIMENSIONS
Part Name
Cylinder Assembly
Rocker Arm Bushings
Intake Valve
Exhaust Valve
Piston (Standard)
Piston Pin Assembly
Feature
Intake Valve Guide Bore
Exhaust Valve Guide Bore
Inside Diameter
Stem Diameter
Stem Diameter
 Diameter at Top
 Diameter Below 1st Groove
 Diameter at Bottom
Pin Bore Diameter
Third Ring Groove Width
Fourth Ring Groove Width
Length (including plugs)
Diameter
New Dimension (inches)
0.5307 - 0.5317
0.5307 - 0.5317
0.5945 - 0.5955
0.3730 - 0.3735
0.3713 - 0.3720
4.4030 - 4.4050
4.3960 - 4.3980
4.4270 - 4.4280
0.9988 - 0.9990
0.1585 - 0.1595
0.0970 - 0.0980
4.410 - 4.430
0.9984 - 0.9986
 Measure piston diameter at right angles to pin bore.
 Measurement must be made at .165 inch from bottom of piston.
16-13
Chapter16
16-5 CYLINDER ASSEMBLY
REPAIR AND REPLACEMENT
CYLINDER HEAD WELD REPAIR
Only minor non-structural weld repairs are permitted.
TCM allows welding repairs of the intake and exhaust
port flanges, rocker cover flange and threaded holes
(other than spark plug) and requires that these repairs
be performed under carefully controlled conditions
using an approved procedure and process which meets
the requirements of the applicable federal aviation
regulations. No structural weld repairs are allowed.
TCM does not allow weld repairs to the combustion
chamber, head structure and rocker shaft bosses Any
cylinder head that is cracked or damaged in a
structural area must be replaced.
WARNING
Welding the cylinder head structure may
destroy the assembly preloads and casting
strength resulting in cylinder assembly failure.
CYLINDER HEAD FIN REPAIR
Do not attempt to straighten cylinder head cooling
fins. If it becomes necessary to cut out a vee notch to
stop a head fin crack, use a slotted drill bushing to fit
over the fin and a 3/16 inch twist drill to cut the notch.
Its apex and edges must be rounded. If such repairs
and previous breakage have removed 10% or more of
the total cylinder head fin area, the cylinder has
reached its limit of cooling fin repair and must be
replaced.
CYLINDER BARREL FINS
Repairs can be accomplished only on fin tips which
are outside of the power stroke stress area of the
cylinder barrel. Reference Figure 16-1.
16-14
Pitting, sharp indentations or chafing damage in the
fin tip LESS than .050 inch deep - Remove only
enough material to eliminate the damage with a small
hand-held grinder and fine grit disk or stone, or by
turning the cylinder on a lathe. Precautions must be
taken to prevent damage to adjacent fins and localized
fin heating during the material removal process. Blend
the area smooth so that no sharp edges remain and
insure that original fin profile and contours are
retained. Inspect the area for cracks.
WARNING
Do not weld cylinder barrel or barrel fins.
CYLINDER BARREL
Any cylinder or cylinder associated parts worn
beyond new parts limits or failing to meet the
inspection criteria in sections 16-1 through 16-5 must
be replaced unless repair is possible with the
following instructions:
Cylinder machining may be accomplished by a repair
facility certified for specialized cylinder repairs.
The cylinder bore may be ground and honed to, but
must not exceed, the maximum allowable 0.015
oversize dimension specified in Figure 16-4,
"Cylinder Dimensions." Grind the cylinder bore with
a cam controlled grinder. Use grinding stones that
will produce an RMS finish of 60 or less. Magnetic
particle inspect cylinder bore after grinding in
accordance with section 5-9. Identify the cylinder
with the correct bore size by steel stamping the
cylinder barrel flange with the appropriate oversize
designation in accordance with Figure 16-16.
Chapter 16
VALVE SEAT REPLACEMENT
Valve seats that are damaged or have worn beyond
acceptable specifications must be replaced using the
following special tools and procedures.
Special Tools Required
1. Borrough's valve seat remover and replacer
8086 or equivalent.
2. Borrough's 5221B cylinder holding fixture
and 5221-15a adapter or equivalent.
3. Borrough's 8122a common drive handle or
equivalent.
4. Valve stem or valve guide hole pilot of
correct size.
5. Valve seat boss cutter of correct size. Use the
cutter size required for new valve seat outside
diameter.
6. Universal drive from Borrough's 8116
common parts kit or equivalent.
7. Heavy duty drill press.
WARNING
Do not use a torch to heat the cylinder
assembly. The heating process must be
performed using uniform heating methods
only. After cylinder has been heated, do not
bump the head or barrel.
To establish an inspection point for head to barrel
movement, mask off a 1/4” wide x 1” high area across
the cylinder head to barrel junction on the intake port
side of the cylinder. Apply a heavy coat of high
temperature paint and allow the paint to dry
thoroughly. Remove the masking material.
After a cylinder assembly has been subjected to a
heating operation, always inspect the cylinder
assembly and insure that the head has not turned in
relation to the barrel. Movement of the head in
relation to the barrel will destroy the assembly
preload. Discard any cylinder with indications of head
to barrel movement.
a cracked valve seat bore or a valve seat bore that has
eroded beyond the allowable valve seat oversize bore
repair.
VALVE SEAT BORE MACHINING
Measure the new valve seat insert outside diameter
and select the proper size valve seat bore cutter. Install
the cylinder in the holding fixture. Using the specified
tools, machine the valve seat bore(s) to the correct
diameter. Deburr the valve seat bore and clean the
cylinder removing all debris from machining
procedure. Inspect and record the valve seat bore
inside diameter and new valve seat outside diameter.
An interference fit of 0.007T to 0.010T is required for
exhaust valve seats. An interference fit of 0.0055T to
0.0085T is required for intake valve seats.
VALVE SEAT INSTALLATION
Heat the cylinder assembly to 450°F maximum. Heat
soak one hour. Using the specified tools, install the
new valve seat(s). The valve seat(s) must be installed
firmly against the bottom of the valve seat bore. Valve
seat(s) that are not seated properly or that are
misaligned will cause valve leakage and burning.
FLUORESCENT PENETRANT INSPECTION
AFTER VALVE SEAT INSTALLATION
After valve seat installation, the cylinder head must be
fluorescent penetrant inspected in accordance with
section 5-12, "Fluorescent Penetrant Inspection."
Structural cracks in the cylinder head are not
acceptable or repairable. Cylinder heads that exhibit
cracks must be discarded.
NOTE…
If valve guides are being replaced this inspection may
be delayed until the valve guides have been installed.
VALVE GUIDE REPLACEMENT
Valve guides worn beyond specification must be
replaced using the following procedure and special
tools:
1. Borrough's 5221b cylinder holding fixture
and 5221-15a adapter or equivalent.
VALVE SEAT REMOVAL
2. Borrough's 4981 remover or equivalent.
Heat the cylinder assembly to 450°F maximum. Heat
soak one hour. Using the correct remover from the list
above, remove the worn valve seat or seats. Allow
cylinder to cool to room temperature. Inspect the seat
bore for cracks and erosion. Discard any cylinder with
3. Valve guide replacer.
4. 3606CP Valve guide stem hole reamer.
5. Proper size morse adapter.
16-15
Chapter16
6. Borrough's
equivalent.
3170
floating
holder
or
7. Heavy duty drill press.
VALVE GUIDE REMOVAL
WARNING
Do not use a torch to heat the cylinder
assembly. The heating process must be
performed using uniform heating methods
only. After cylinder has been heated, do not
bump the head or barrel.
Allow the cylinder to stabilize to room temperature
and inspect the valve guide inside diameter. If
necessary ream the valve guide inside diameter to the
required specifications.
CYLINDER HEAD FLUORESCENT
PENETRANT INSPECTION
After valve guide installation, the cylinder head must
be fluorescent penetrant inspected in accordance with
section 5-12, "Fluorescent Penetrant Inspection."
Structural cracks in the cylinder head are not
acceptable or repairable. Cylinder heads exhibiting
cracks in the structure must be discarded.
REAMING VALVE GUIDES
Install proper size head on removing tool. Attach to
cold water supply. Heat the cylinder to 450° F. Heat
soak one hour. Install cylinder in the holding fixture.
Install pilot into guide. Hold valve guide removal tool
down firmly into guide bore with hand on water
release button. Use other hand to work sliding
hammer. Release the water and hammer out guide
while water is running. Both guides can be removed
with one heating. Allow cylinder to cool to room
temperature.
The intake and exhaust valve guide bore inside
diameters are prefinished and will conform to the
required specifications when installed under
controlled production procedures. However, field
repair conditions may vary and some valve guide
bores may require a finish reaming operation in
accordance with the following procedures.
VALVE GUIDE BORE MACHINING
Do not attempt this procedure with a hand
held power tool.
CAUTION…
Always ream guide bore to the proper oversize. Never
install an oversize guide in the old bore.
Measure valve guide bore and select proper size
reamer. Install cylinder in holding fixture. Ream valve
guide bore to required oversize. Guide bore must be
free of grooves. Deburr the valve guide bore and clean
the cylinder removing all debris from the machining
procedure. Inspect the valve guide bore new inside
diameter and new valve guide outside diameter. An
interference fit of 0.001T to 0.0025T is required for
exhaust and intake valve guides.
VALVE GUIDE INSTALLATION
CAUTION…
The intake and exhaust valve guides are different and
must be installed in the correct positions.
Apply a small amount of LUBRIPLATE® 930AA to
the outside diameter of the guide to reduce the chance
of binding during installation. Heat the cylinder
assembly to 450°F maximum. Heat soak for one hour.
Using the specified installation tool install the new
valve guides.
16-16
WARNING
Install the holding fixture into drill press. Index
fixture to proper angle and install cylinder into fixture.
Zero in guide with dial indicator. Using the proper
size reamer, ream the valve guides. Ream at 400 RPM
for high speed steel reamers and 700 RPM for
Carbide tip reamers using plenty of lubricant.
Inspect finished bore size to the required specification.
Refer to Figure 16-4, "Cylinder Dimensions," for
correct stem hole finished sizes.
The valve guide finish must be 32 RMS inspect finish
with a profilometer.
VALVE SEAT REFACING
Valve seat refacing must be performed in accordance
with the specifications shown in Figures 16-5 and 166, "Intake and Exhaust Valve Seat Refacing," using
the following special tools:
Chapter 16
1. Sioux Brand" Valve Seat Grinder Set No.
1675 or equivalent.
2. Valve Seat Grinder Pilot- check valve guide
inside dia. for proper size.
3. Grinding Stones K498 roughening and K428
finishing for intake valve seats
K491 roughening and K421 finishing for
exhaust valve seats.
45° Grinding Stones K28 roughening and
K98 finishing for intake valve seats
CAUTION…
Valve seats and valves may be lapped after refacing if
desired. Lapping compounds are extremely abrasive
and must be completely removed from the valves,
valve seats and cylinder by cleaning thoroughly using
hot soapy water and a stiff bristled scrub brush. All
lapping compound must be removed from cylinder.
After washing, all soap residue must be removed by
thoroughly rinsing with hot water. The cylinder must
be dried completely and all bare steel surfaces
thoroughly coated with clean 50 weight aviation
engine oil.
K91 roughening and K21 finishing for
exhaust valve seats.
4.
Borrough's 5221B Cylinder Holding Fixture
and 5221-15A Adapter or equivalent.
16-17
Chapter16
FIGURE 16-5. INTAKE VALVE SEAT REFACING
FIGURE 16-6. EXHAUST VALVE SEAT REFACING
16-18
Chapter 16
CYLINDER BORE FINISH
EQUIPMENT
Use a wet honing process and hone stones that will
produce a surface finish as specified below.
After honing the cylinder barrel to the required
specifications, inspect the cylinder barrel wall for
corrosion, pitting and scoring. Discard cylinders
exhibiting any of the above indications.
Surface finish measurements are to be made with a
Hommel Tester T500 part number 191800. The
software for receiving data from the tester is Hommel
America TIOOO Turbo. Both the tester and software
are available from Hommel America, New Britain,
CT. The tester is to be set to inch units, traverse
lengths Lt of .19 and Lm of .16, a cutoff length (Lc)
of 0.03, Ml filter, and R profile (Prof).
CROSS HATCH PATTERN
The bore finish shall show a cross hatch pattern
produced by a wet honing process. The included angle
of the cross hatch measured perpendicular to the axis
of the cylinder shall be 22 to 32 degrees. Hone turn
around areas up to 0.5 inch from the skirt and barrel
stop are exempt from cross hatch angle requirements
SURFACE FINISH SPECIFICATION
The surface finish of the cylinder barrel bore must
meet the values listed in the table below.
The hone pattern as taken by fax film and viewed at
100X shall be cleanly cut and substantially free of
torn and folded metal.
The cylinder bore must be cleaned thoroughly using
hot soapy water and a stiff bristled scrub brush. All
honing material must be removed from cylinder. After
washing, all soap residue must be removed by
ITEM
1.
2.
3.
4.
SYMBOL
Ra
Sk
R3Z
RPM/Rz
thoroughly rinsing with hot water. The cylinder must
be dried completely and all bare steel surfaces
thoroughly coated with clean 50 weight aviation
engine oil.
SPARK PLUG HELICAL COIL INSERT
REPLACEMENT
Spark plug helical coil inserts that require replacement
as determined by the inspection procedures in section
16-4 must be replaced using the following
instructions. Before attempting to back out a damaged
insert, use a sharp pointed tool to pry the teeth at the
outer helical coil end away from the cylinder head
metal. Tap a helical coil extracting tool into the insert
until it has a good bite. See Figure 16-8, "Removing
Spark Plug Hole Helical Coil Insert." Using the
proper size mandrel on installing tool, place a new
helical coil in the cutout side of the installing tool and
engage the driving tang toward the threaded end.
Engage the tang with the slotted end of the driving
mandrel and wind the insert into the sleeve thread
compressing the insert. Hold the sleeve so the helical
coil can be seen through the slot in the threaded end.
Turn the mandrel crank until the insert starts into the
cylinder head hole. If the sleeve is not in contact with
the head surface, grip sleeve and mandrel and turn
until the sleeve touches lightly. See Figure 16-9,
"Installing Spark Plug Hole Helical Coil Insert." Wind
the helical coil into the cylinder head until its toothed
end lies within the first full thread. The teeth should
be in position to enter the depressions made by the
original insert. If driven too far, the insert will emerge
in the combustion chamber and will have to be wound
through and removed. When the helical coil is in the
correct position, use long-nose pliers to bend the
driving tang back and forth across the hole until it
breaks off at the notch.
NAME
RANGE
Arithmetic average surface roughness
30 - 50 micro inches
Skew, a measure of plateau
-1. to -3.5
Three point height, distance between third highest 130 - 275
peak and third lowest valley
micro inches
Ratio of mean peak to total depth of pattern
< .35
16-19
Chapter16
Coat a Heli-Coil Corporation Number 520-2
expanding tool, threaded end, with Alcoa thread lube
or a mixture of white lead and oil. Screw the
expanding tool into the new insert until its final thread
forces the teeth firmly into the cylinder head metal.
See Figure 16-10, "Expanding Spark Plug Hole
Helical Coil Insert." See Figure 16-2, "Cylinder Stud
Setting Heights," for proper spark plug helical
coil depth.
CAUTION…
Replacement helical coils must be stainless steel.
WARNING
The helical coil insert end must not protrude
into the combustion chamber after it has
been installed.
CYLINDER STUD INSTALLATION
FIGURE 16-7. PRYING SPARK PLUG
HELICAL COIL AWAY FROM CYLINDER
FIGURE 16-9. INSTALLING SPARK PLUG
HELICAL COIL
FIGURE 16-8. REMOVING SPARK PLUG
HOLE HELICAL INSERT
FIGURE 16-10. EXPANDING SPARK PLUG
HOLE HELICAL INSERT
16-20
Chapter16
FIGURE 16-11. ROCKER ARM BUSHING REPLACEMENT
Install new exhaust flange studs, rocker shaft hold
down studs and new intake flange studs of the
appropriate oversize as determined by dimensional
inspection in accordance with Figure 16-2 and section
5-22.
CYLINDER PROTECTIVE COATING
1. Clean the exterior cylinder head surface and apply
a protective coating of Accelagold aluminum
conversion in accordance with section 5-20.
WARNING
2. Thoroughly clean the entire cylinder with mineral
spirits and air dry. Mask the cylinder flange nut
seat contact surfaces, cylinder skirt and flange to
crankcase mating surfaces. Apply a protective
coating of specified TCM enamel paint or
equivalent to the cylinder barrel in accordance
with section 5-20.
3. After the paint has dried completely, remove all
masking materials and coat all bare steel surfaces
with clean 50 weight aviation engine oil. Store the
cylinder assembly in a clean protected area until
cylinder subassembly.
Do not paint the cylinder flange nut seats,
skirt or flange to crankcase mating surface.
16-21
Chapter 16
ROCKER ARM BUSHING REPLACEMENT
1. The same tool used to remove the old bushings
from the rocker arm(s), if properly designed, can
be used to install the new bushings in the rocker
arm(s).
2. Oil the new bushing with clean 50 weight
aviation engine oil and press the new bushings in
flush with to 0.020” below surface of the rocker
hub.
CAUTION…
Before reaming rocker arms plug the oil passages
with beeswax.
3. Ream the new bushings to the diameter specified
in Figure 16-11, "Rocker Arm Bushing
Replacement." Lightly break the sharp edge at
each end of new bushings. Inspect the bushing
size and RMS finish to the required
specifications.
ROCKER ARM TO ROTOCOIL CLEARANCE
MACHINING
1. See Figure 16-12. A minimum clearance of .020
inch must be maintained between the rocker arm
and rotocoil at the time of assembly.
2. If the minimum clearance of .020 is not present at
the time of assembly, it is permissible to smoothly
grind across the forging flash line on the
underside of the rocker arm to obtain the specified
clearance. Prior to grinding, the rocker arm
bushing bore and oil passage must be protected to
prevent debris entry. The grind must not exceed
the width illustrated in Figure 16-12. If the
required clearance cannot be obtained without
exceeding this grind width, the rocker arm must
be replaced.
CAUTION…
After reaming, clean and flush the oil passages using
clean solvent. Insure that the oil passages are clear of
any debris, contamination or beeswax.
Any rocker arms with obstructed oil passages
must be cleared by flushing with mineral spirits.
Any rocker arm with obstructed oil passages that
cannot be cleared must be discarded.
FIGURE 16-12. ROCKER ARM TO ROTOCOIL CLEARANCE
16-22
Chapter16
3. The grind must be smooth and uniform. All of the
ground surface must be polished to remove all
grinding marks. Remove the protective coverings
from the rocker arm and clean thoroughly. The
rocker arm must be magnetic particle inspected
for cracks following the polishing operation.
WARNING
The presence of grinding marks or cracks in
the rocker arm may cause the rocker arm to
fail.
4. Thoroughly clean the rocker arm(s) before
assembly on the engine.
FIGURE 16-13. INTAKE VALVE REFACING
16-23
Chapter 16
INTAKE VALVE GRINDING
1. Clean the intake valves with mineral spirits.
2. Using a valve grinding machine and proper valve
grinding wheel, grind the intake valve contact seat
at 59°- 45' to 60°-15' to remove any indication of
wear. This will increase the distance from the new
gauge line to the valve stem tip. See Figure 16-13,
"Intake Valve Refacing."
3. Clean the valve using mineral spirits.
4. Using the gauge line inspection fixture, measure
the dimension from the gauge line to the bottom
of the valve. This dimension must be no less than
.100". Reground valves not conforming to this
criteria must be discarded. Valves conforming to
this criteria must have the tip ground to maintain
the tip to gauge line dimension of 4.246" to
4.252".
5. After valve tip grinding, measure the intake valve
overall length. The valve overall length cannot be
16-24
less than 4.352". Discard valves that are less than
4.352" in length.
6. After grinding process thoroughly clean the valve
with mineral spirits and air dry.
7. Using a vee block with a surface plate and a dial
indicator, inspect each intake valve face for
run-out (eccentricity). Intake valves exceeding
.002" total indicator reading must be discarded.
8. Using an optical comparator, inspect the valve
contact seat angle. Intake valve face angles which
do not conform to 59°- 45' to 60°-15' must be
discarded.
9. Using a profilometer, inspect the valve contact
seat finish. Intake valves exceeding 25 RMS must
be discarded.
10. Perform magnetic particle inspection on the
valves. Discard any valve with cracks or
indications of cracks. Clean the valves using
mineral spirits and air dry. Coat all surfaces
thoroughly with clean 50 weight aviation engine
oil.
Chapter16
FIGURE 16-14. VALVE GAUGE LINE INSPECTION FIXTURE
16-25
Chapter 16
16-6
CYLINDER AND PISTON
SUBASSEMBLY
Original cylinders have a position number stamped on
the edge of the base flange. New cylinders must have
a position number (1 through 6), as used, stamped in
the location shown in Figure 16-15.”
New pistons must have a position number (1 through
6) stamped in the location shown in Figure 16-15,
"Cylinder And Piston Position Number."
WARNING
Improper use of sealants and lubricants may
cause engine malfunction or failure.
1. Insure the piston and piston rings are the correct
size for the cylinder bore size. Inspect the piston
to cylinder clearance of each matching piston and
cylinder in accordance with Figure 16-4.
FIGURE 16-15. CYLINDER AND PISTON POSITION NUMBER
FIGURE 16-16. VALVE AND SPRING INSTALLATION
16-26
Chapter16
2. Each piston ring must be inspected for proper gap
in the cylinder bore in which it will be assembled.
Insert one ring at the time into the cylinder bore
and push it to the position specified in the table of
limits using the piston. Remove the piston and
inspect the ring gap using a leaf type feeler gauge.
If the ring gap is smaller than specified, record
actual gap size and remove the ring from the
cylinder bore. Mount a fine toothed flat file in a
vise. Holding the ring ends firmly and squarely
against the file, remove the desired amount of
material. Deburr the ring gap ends using crocus
cloth. Thoroughly clean the ring with mineral
spirits and air dry. Install the ring in the cylinder
bore to the correct position and inspect the ring
gap. Repeat the above procedure until all ring
gaps meet the required specification. Do not use
rings that are not within the specified ring gap
dimensions.
4. See Figure 6-15. Install baffles (44) and springs
(45) on all cylinders. Install baffle as shown in
Figures 16-17 and 16-18. Insert the spring
through cylinder. Using another spring or a hook
fashioned from stiff wire, hook and pull the
spring end over the cylinder fin. Immediately
before cylinder subassembly, thoroughly clean
the cylinder bore using hot soapy water and a
hard bristled scrub brush. After washing, all soap
residue must be removed by thoroughly rinsing
with hot water. The cylinder must be dried
completely and all bare steel surfaces thoroughly
coated with clean 50 weight aviation engine oil.
NOTE…
Gap for second ring must be at least .006 larger than
gap for top ring.
3. Thoroughly clean the cylinder baffles, cylinder,
valves, valve springs, retainers, rotocoils, valve
spring retainer keys, pistons, piston rings, piston
pins, pushrod housings, springs and washers with
mineral spirits and air dry. Inspect all parts for
any damage that may have occurred during
handling or shipment.
FIGURE 16-18. SECURING BAFFLE
FIGURE 16-17. INSTALLING BAFFLE
5. See Figure 6-15, "Cylinder and Piston
Assembly." Using the following instructions,
assemble each of the six cylinders. If the valves
have been lapped, they must be installed into the
positions for which they were lapped. Spread a
film of Molyshield grease on the intake valve
stem (12) and the exhaust valve stem (11). Install
valves into the correct location. Grasp the valve
stems and install the cylinder on a cylindrical
block of wood anchored to a work bench. Again
apply Molyshield grease to valve stems. Place
valve spring retainers (15) over valve guides (4
and 6), cupped side up. Coat the sealing surface
of a new intake valve guide seal with clean 50
weight aviation engine oil. Install new seal (5) on
the intake valve guide by hand. See Figure 16-19
for valve guide seal installation tool and correct
installation. Using the specified installation tool
and a plastic mallet tap the seal on to the guide
16-27
Chapter 16
until it is firmly seated. Install new inner and
outer valve springs (13, 14) and new rotocoils
(16). The valve springs must be installed with the
closed coils toward the cylinder head as shown in
Figure 16-16, "Valve and Spring Installation."
CAUTION…
Do not allow the valve spring compressing tool to
cock the rotocoils. Contact between the rotocoils and
valve stems will cause damage to the valve stems.
6. Using a valve spring compressor, compress the
valve springs and insert the valve stem retainer
keys (17). The springs should be depressed only
enough to admit the keys to seat into the valve
stem grooves. If keys drop too far, they may
become fouled. This condition could cause them
to damage the stem when the springs are released.
Make sure the keys are properly seated into the
grooves of the valve stem before releasing
pressure on springs. Remove the cylinder from
fixture and set it upright on the workbench. Place
a plastic mallet squarely on the end of the valve
stem and strike the plastic mallet sharply with a
rawhide mallet to insure correct seating of valve
retainer keys. DO NOT STRIKE ROTOCOIL.
Insure the valve spring retainer keys are properly
positioned.
7. Carefully position each cylinder assembly so the
cylinder bore is facing upward and the cylinder is
resting on the rocker shaft mounting bosses. Place
a new cylinder base packing (1) on the cylinder
skirt and push it against the base flange. Make
sure the cylinder base packing is not twisted.
Using clean 50 weight aviation engine oil, coat
the cylinder barrel wall thoroughly. Assemble the
remaining five cylinders using the above
instructions.
8. Using the following instructions, assemble each
of the six new pistons and rings.
9. See Figure 6-15. Install all rings with the part
number toward the top of the piston. Install the
16-28
expander (51) into the third ring groove first by
disconnecting it and then reconnecting it fully.
With a ring expander place the oil ring (52) over
the expander with the ring gap positioned 180°
from the expander joint. With a ring expander,
install ring (53) into the second ring groove,
install ring (54) into the first ring groove and
install ring (49) into the fourth ring groove.
10. Inspect all ring side clearances with the ring edge
flush with the piston outside diameter. All ring
side clearances must conform with the dimensions
in “Cylinder And Associated Parts Fits And
Limits.”
NOTE…
Weight differences of piston pairs in opposing bays
must not exceed 1/2 ounce or 14.175 grams.
11. Lubricate the piston pin and piston and ring
assemblies with clean 50 weight aviation engine
oil. Place the new piston and ring assembly with
the cylinder assembly for which it was previously
sized and gapped. Place a new piston pin with
each piston and ring assembly. Install the piston
pins in the piston pin bores. The piston pins must
slide freely in the piston pin bores.
12. Position the rings so the ring gaps are 180° apart
with the first or top ring gap toward top of the
piston Using a ring compressor, install each
piston into it's cylinder so that the top three rings
are in the cylinder barrel and the piston pin is
accessible for installation on the connecting rod.
Install the piston and ring assemblies into the
cylinder bore with the piston position number
toward the propeller flange when the cylinder is
installed on the engine.
13. Place the cylinders on a clean protected work
bench in position order and cover until final
engine assembly.
Chapter16
14. Install new gasket (37) on cylinder end of
pushrod housings (36). Place two each, pushrod
housings, new springs (38), washers (39), new
packings (40) and second washer (39) with each
cylinder.
FIGURE 16-19. VALVE GUIDE SEAL INSTALLATION
16-29
Chapter16
INTENTIONALLY
LEFT
BLANK
16-30
Chapter 17
CHAPTER 17
CRANKCASE
SECTION
17-1
17-2
17-3
17-4
17-5
FIGURE
17-1
17-2
17-3
17-4
17-5
17-6
PAGE
Crankcase Studding Disassembly ............................... 17-2
Crankcase and Associated Parts Cleaning .................. 17-2
Crankcase and Associated Parts Inspection ................ 17-2
Crankcase and Associated Parts
Repair and Replacement.............................................. 17-9
Crankcase Sub-Assembly............................................ 17-11
PAGE
Inspection Of Crankcase Non Critical Area................ 17-3
Inspection Of Crankcase Critical (white)
and Non Critical (shaded) Areas ................................. 17-4
Crankcase Stud Setting Heights ................................. 17-6
Crankcase Dimensional Inspection
Torquing Sequence...................................................... 17-7
Crankcase Fits and Limits ........................................... 17-8
Crankcase Cylinder Deck Helical Coil Installation .... 17-9
17-1
Chapter 17
17-1
CRANKCASE STUDDING
DISASSEMBLY (See Figure 17-3.)
1. Studs, dowels and helical inserts should only be
removed for replacement when they are found to
be loose, corroded, pitted or damaged. Refer to
Sections 17-3 and 17-4 for stud, dowel, and
helical insert replacement.
2. Remove starter shaftgear bushing (2).
3. Crankcase plugs must be removed to allow
pressure flushing of the crankcase halves.
4. Do not attempt to remove oil squirt nozzles field
replacement is not possible.
NOTE…
When plugs are removed they must be identified by
tagging. During crankcase sub-assembly, all plugs
must be placed back in the same crankcase location
from which they were removed to prevent oil pressure
loss.
17-2
CRANKCASE AND
ASSOCIATED PARTS
CLEANING
The crankcase halves must be cleaned in accordance
with the instructions in Section 5-7, "General
Cleaning," and the following special instructions:
1. All through bolts, bushings, bearings, thrust
washers, gaskets, packings, rubber shock mounts,
o-rings, seals, lock washers and self locking nuts
removed from the crankcase must be replaced
100% at overhaul. Cleaning these parts is not
required.
2. The crankcase oil passages must be pressure
flushed with mineral spirit solvent and inspected
with the aid of a flashlight. The crankcase oil
squirt nozzles must be flushed with mineral spirit
solvent to insure they are not obstructed. Use
caution when flushing the oil squirt nozzles
because they are not field replaceable.
17-2
3. The engine mount brackets must be cleaned using
mineral spirit solvent. Insure that the engine
mount oil cooler bracket oil passages are
thoroughly flushed and unobstructed.
4. If the crankcase castings are immersed in an
alkaline bath, they must be sprayed with steam to
remove all traces of alkaline. After the castings
dry, inspect them for any alkaline residues. If
necessary, re-spray with steam to remove
remaining residue. The crankcase and all oil
passages must be thoroughly flushed with mineral
spirit solvent after any alkaline cleaning process
has been used.
CAUTION…
Alkaline cleaning solutions will cause corrosion to
metals if not completely removed.
17-3 CRANKCASE AND
ASSOCIATED PARTS
INSPECTION
VISUAL INSPECTION
The crankcase and associated components must be
visually inspected in accordance with instructions in
Section 5-8, "Visual Inspection," and the following
special instructions:
1. Visually inspect the inside and outside of both
crankcase halves for cracks. Pay particular
attention to areas on and adjacent to the cylinder
mount flanges, tappet guides, case flange, nose
seal land and bearing bosses. Look for scoring in
the old crankshaft bearings. Look for scoring in
the tappet guides and camshaft bearings. Inspect
main bearing boss parting surfaces for fretting.
Inspect the bearing saddles for bearing lock slot
elongation and any indications of bearing
movement. Visually inspect all machined surfaces
for nicks and roughness.
Chapter 17
2. Use the following to determine if a cracked
crankcase can be repaired. See Figures 17-1 and
17-2.
If a crack is observed in any non-critical (shaded)
area that is more than two (2) inches in length, or
if a previously observed crack has progressed to
two (2) or more inches in length, the crankcase
must be repaired or replaced. If any crack is
observed in a critical (white) area the crankcase
must be discarded.
Reasons for crankcase replacement:
a. Any crack in the critical (white) areas.
b. Any crack two (2) inches or more in length in
the non-critical (shaded) area.
c. Any crack that is leaking oil (not seeping).
FIGURE 17-1. INSPECTION OF CRANKCASE NON CRITICAL AREAS
4. Visually inspect the breather for cracks and dents.
Inspect tube ends for scoring and out of roundness
that may have caused a bad seal and oil leakage.
Discard components with any of these
indications.
5. Visually inspect all pipe plugs for stripped or
distorted threads and damaged wrench flats. Pipe
plugs exhibiting damaged threads or wrench flats
must be discarded.
6. Inspect engine mount brackets and alternator
support bracket for cracks, dents and wear.
Inspect hardware for distorted, stripped threads
and damaged wrench flats. Components
exhibiting any of the above indications must be
discarded. Inspect tapped holes and helical coils
for
distorted
or
stripped
threads.
17-3
Chapter 17
FIGURE 17-2. INSPECTION OF CRANKCASE CRITICAL (WHITE) AND
NON CRITICAL (SHADED) AREAS
4. Visually inspect all crankcase helical coils and
studs for stripped or distorted threads. Inspect
studs for corrosion, rusting, pitting, incomplete
threads and looseness. Check all studs with a tool
maker's square for alignment. Check studs for
17-4
looseness. All studs must have their setting
heights checked for indications of backing out.
See the following for crankcase stud setting
heights.
Chapter 17
NOTE…
All studs, helical coils and plugs must be installed in
accordance with the instructions in Sections 5-21,
5-22 and 5-24. See Figure 5-2, "Standard And
Oversize Stud Identification."
CRANKCASE STUD SETTING HEIGHTS (See Figure 17-3.)
ITEM
NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
PART LOCATION
THREAD SIZE
QTY.
——
SETTING
HEIGHT
2.19
Breather Front 1-3-5 Side Crankcase
Bushing,
Starter
Shaftgear,
Between
Crankcase Halves
Stud, Cylinder Mount Deck
Stud, Governor Pad
Bushing Reducer, 2-4-6 Side Crankcase
Elbow, 2-4-6 Side Crankcase
Swivel, Tee, 2-4-6 Side Crankcase
Reducer, Orifice, 2-4-6 Side Crankcase
Nut, 2-4-6 Side Crankcase
Stud, Crankcase, Engine Mount
Stud, 1-3-5 Side Crankcase
Stud, 2-4-6 Side Crankcase
Plug, 2-4-6 Side Crankcase, Front
Plug, Both Crankcase Halves, Front
Housing, Oil gauge, 2-4-6 Side Crankcase
Rear
Gasket, 2-4-6 Side Crankcase
Plug, 2-4-6 Side Crankcase
Dowel, Crankcase Rear
Dowel, Both Crankcase Halves, Rear
Stud, Both Crankcase Halves, Rear
Stud, Both Crankcase Halves, Rear
Stud, Both Crankcase Halves, Rear
Stud, Fuel Pump Pad
Stud, Oil Sump Mount Flange
——
3/8-16x3/8-24
5/16-18x5/16-24
——
——
——
——
——
3/8-16x3/8-24
3/8-16x3/8-24
3/8-16x3/8-24
——
——
——
——
.78
1.38
——
——
——
——
——
1.19
1.69
1.69
——
——
——
1
36
4
1
1
1
1
1
4
3
1
11
21
1
——
——
——,
——
5/16-18x5/16-24
5/16-18x5/16-24
5/16-18x5/16-24
5/16-18x5/16-24
1/4-20x1/4-28
——
——
.05 - .07
.31
.84
2.00
1.37
.75
.75
1
1
1
2
3
3
2
4
14
1
17-5
Chapter 17
FIGURE 17-3. CRANKCASE STUD SETTING HEIGHTS
17-6
Chapter 17
FLUORESCENT PENETRANT INSPECTION
The crankcase halves and all aluminum alloy brackets
must be fluorescent penetrant inspected by a certified
technician in accordance with the instructions in
Section 5-12, "Fluorescent Penetrant Inspection.
Crankcase halves that exhibit cracks must be
discarded or repaired in accordance with the
instructions in Section 17-4.
NOTE…
Prior to dimensional inspection of the crankcase
crankshaft and camshaft bores the crankcase must be
assembled and torqued in accordance with the
following:
1. All crankcase attaching hardware must be torqued
to the sequence specified in Figure 17-4.
2. Use 1/4 inch thick cadmium plated washers at
cylinder 7/16 inch through bolt locations.
3. Torque 7/16 inch nuts at positions 9, 10, 12, 13 to
a preliminary value of 225 inch pounds.
4. Torque 7/16 inch nuts at positions 1, 2, 4, 5, 7, 8
to a preliminary value of 250 inch pounds.
5. Torque 3/8 inch nuts to a preliminary value of
150 inch pounds.
6. Torque 1/4 inch nuts to a preliminary value of 57
inch pounds.
7. Torque 7/16 inch nuts at positions 9, 10, 12, 13 to
a final value of 450 inch pounds.
8. Torque 7/16 inch nuts at positions 1, 2, 4, 5, 7, 8
to a final value of 500 inch pounds.
9. Torque 3/8 inch nuts to a final value of 300 inch
pounds.
10. Torque 1/4 inch nuts to a final value of 114 inch
pounds.
NOTE…
See "New Parts Dimensions," of this section for
crankcase bore diameters.
FIGURE 17-4. CRANKCASE DIMENSIONAL INSPECTION TORQUING SEQUENCE
17-7
Chapter 17
DIMENSIONAL INSPECTION
The following new parts limits must be used for dimensional inspection. Components that do not meet the
following specifications must be discarded.
All components must be thoroughly cleaned and air dried prior to dimensional inspection.
Ref.
No
1.
2.
3.
4.
5.
6.
Description
CRANKCASE
Through bolt in crankcase ............................................................. Diameter:
Hydraulic valve tappet in crankcase.............................................. Diameter:
Governor driven gear in crankcase................................................................:
Starter shaft bushing in crankcase .................................................................:
Crankcase (each half).......................................................................... Width:
Crankcase (cylinder deck-to- cylinder deck)...................................... width:
NOTE…See Critical New Parts Dimensions for crankcase bores.
FIGURE 17-5. CRANKCASE FITS AND LIMITS
17-8
New Parts
Min.
Max.
0.0007T
0.001L
0.0014L
0.0005L
4.559
9.118
0.0011L
0.0025L
0.0034L
0.001T
4.565
9.130
Chapter 17
NEW PARTS DIMENSIONS
Part Name
Crankcase
Feature
Crankshaft front journal bore
Crankshaft rear and intermediate journal bores
Thrust washer lands diameter
Camshaft bore diameter
Tappet guides diameter
Starter shaftgear bushing hole diameter
Camshaft journal diameter
17-4
CRANKCASE AND
ASSOCIATED PARTS REPAIR
AND REPLACEMENT
Any crankcase or associated parts worn beyond new
parts limits or failing to meet inspection criteria in
Section 17-3 must be replaced 100% unless repair is
possible with the following instructions:
1. Crankcases with cracks must be repaired or
replaced. Teledyne Continental Motors has
established that welding of crankcases is an
acceptable repair process. Weld repairs in the
crankcase non critical areas shown in Figures
17-1, 17-2 may be accomplished by a repair
New Dimension
(inches)
2.4370 - 2.4380
2.5625 - 2.5635
3.410 - 3.420
1.3745 - 1.3755
1.0005 - 1.0015
1.2500 - 1.2510
1.3725 - 1.3735
facility certified for specialized crankcase
repairs.
The dimensional integrity of the crankcase must
be maintained.
WARNING
No weld repairs are allowed in the critical
areas shown in Figures 17-1 and 17-2.
2. Installation of crankcase cylinder deck stud hole
helical coils must be accomplished in accordance
with the specifications in Figure 17-6 and the
instructions in Section 5-21, "Helical Coil Insert
Replacement."
FIGURE 17-6. CRANKCASE CYLINDER DECK HELICAL COIL INSTALLATION
17-9
Chapter 17
WARNING
The 2 and 4 o'clock crankcase cylinder deck
stud positions must not be repaired by helical
coil insert installation.
3. Any crankcase stud found to be damaged or loose
must be replaced in accordance with the
instructions in Section 5-22. See Figure 17-3,
"Crankcase Stud Setting Heights," for proper stud
setting heights. See the following for crankcase
cylinder mount deck studs.
NOTE…
Crankcase cylinder mount deck studs requiring
replacement must be replaced in accordance with the
following instructions:
a. Studs and tapped holes must be clean and dry.
b. Apply Lockquick Primer grade "N" to stud
and cylinder deck threads and allow to dry.
c. Apply Loctite grade 271 to both threads.
d. Install studs to appropriate setting height. See
Section 17-3.
e. Wipe excess Loctite from cylinder deck.
f.
Allow two hours minimum setting time
before testing stud break away torque.
g. Test studs after they have cured. The studs
must not break away under a torque load of
100 inch pounds.
h. Studs conforming with the break away toque
test can be utilized for cylinder installation.
4. Crankcases with crankshaft or camshaft bearing
bores that exceed the specified critical new parts
diameter must be discarded or line bored oversize.
Line boring may be accomplished by a repair
facility certified for specialized crankcase
repairs. See Section 17-3 for new parts
dimensions.
17-10
5. Crankcase halves exhibiting fretting must be
machined or discarded. Crankcase machining
may be accomplished by a repair facility
certified for specialized crankcase repairs. The
crankcase parting line to cylinder deck new parts
dimension is 4.559 minimum to 4.565 maximum.
After machining process the service minimum
cylinder deck height dimension must not exceed
4.5535 minimum. Crankcase halves exceeding
this dimension must be discarded.
CAUTION…
Gear backlashes must not be less than the specified
minimum after machining.
6. The case half parting line surface must be flat
within .005 true indicator reading but not to
exceed cumulative of .008 true indicator reading
with mating crankcase half. Crankcase halves
exceeding these dimensions must be discarded.
After all machining procedures have been
completed the crankcase halves must be
fluorescent penetrant inspected by a certified
technician as specified in Section 17-3 in
accordance with Section 5-12, "Fluorescent
Penetrant Inspection."
7. Section 5-19, "Application Of Accelagold,"
applies to all aluminum alloy castings, sheet metal
and tubing.
Chapter 17
17-5
CRANKCASE
SUB-ASSEMBLY
NOTE…
All crankcase components must be clean and free of
debris before assembly.
1. See Figure 17-3, "Crankcase Stud Setting
Heights." Install all pipe plugs that were removed
in accordance with the specifications in Figure
17-3 as applicable. Before installation, apply
Loctite Pipe Sealant with Teflon (PS/T) sparingly
on the pipe plug male threads. Install and torque
plugs to the specified values in Table 6-3, "Pipe
Plug Torques."
2. Install a new oil gauge lock ring (10) on oil gauge
housing (9). Assemble housing (9) to crankcase
oil gauge housing extension using a new hose (8)
and two clamps (7). Torque clamps (7) to 12-16
inch pounds.
3. Cover and store crankcase halves and associated
parts in a clean protected area until final engine
assembly.
17-11
Chapter 17
INTENTIONALLY
LEFT
BLANK
17-12
Chapter 18
CHAPTER 18
ENGINE DRIVE TRAIN
SECTION
18-1
18-2
18-3
18-4
18-5
18-6
PAGE
Camshaft Disassembly ....................................................18-2
Crankshaft and Connecting Rod Disassembly ...............18-2
Engine Drive Train Cleaning ..........................................18-2
Engine Drive Train Inspection ........................................18-3
Engine Drive Train Repair and Replacement .................18-9
Engine Drive Train Sub-Assembly .................................18-17
FIGURE
18-1
PAGE
Crankshaft, Camshaft and Connecting Rod
Fits And Limits................................................................18-6
Connecting Rod Fits And Limits ....................................18-8
Crankshaft Hanger Blade Bushing Replacement ...........18-10
Counterweight Inspection, Repair and Installation.........18-12
Oil Control Plug Installation Tool...................................18-13
Oil Control Plug Leak Test Fixture.................................18-14
Crankshaft Leak Test.......................................................18-15
Helix Pattern Application................................................18-16
Connecting Rod Position Number ..................................18-19
18-2
18-3
18-4
18-5
18-6
18-7
18-8
18-9
18-1
Chapter 18
18-1 CAMSHAFT
DISASSEMBLY (See Figure 6-18)
See Figure 6-18, "Camshaft Assembly." Remove the
governor drive gear (5) and woodruff key (4). Cut and
remove lockwire from bolts (3). Remove four bolts
(3) and camshaft gear (2). Discard woodruff key (4)
and lockwire.
18-2 CRANKSHAFT AND
CONNECTING ROD
DISASSEMBLY (See Figure 6-19)
1. See Figure 6-19, "Crankshaft Assembly." Use
wooden support blocks under the front and rear
main journals of the crankshaft during
disassembly. Remove and discard cotter pins (23),
nuts (21) and bolts (20). Separate connecting rod
caps and rod (18). Remove and discard bearing
inserts (22). Loosely reassemble rods, caps, bolts
and nuts with their position numbers matched.
2. Remove and discard retaining rings (8), plates (7)
and pins (5, 6). Lift counterweight assemblies (3)
from crankshaft.
3. Cut safety wire and remove four bolts (15) and
gear (14). Tap circumference on gear using a
rawhide mallet and remove.
4. Work oil seal spring (17) from oil seal groove and
detach from seal. Twist and remove oil seal from
crankshaft. Discard oil seal (16) and spring (17).
WARNING
The counterweights and crankshaft must not
be punch marked or scribed for location
identification. Use tagging or ink methods to
identify.
18-3
ENGINE DRIVE TRAIN
CLEANING
The camshaft, crankshaft, connecting rods and their
associated parts must be cleaned in accordance with
the instructions in Section 5-7, "General Cleaning,"
and the following special instructions:
1. All hydraulic tappets, woodruff keys, rubber oil
seals, springs, crankshaft main bearings, thrust
washers, connecting rod bearings, counterweight
pins, retainer plates, snap rings, o-rings and cotter
18-2
pins removed from the camshaft, crankshaft and
crankcase must be replaced 100% at overhaul.
Cleaning of these parts is not required.
Crankshaft counterweight hanger blade bushings,
counterweight bushings and connecting rod
bushings must also be replaced 100% at overhaul.
2. All areas of the camshaft and crankshaft must be
degreased by brushing or spraying with mineral
spirit solvent. The crankshaft crank pins, main
journals, oil seal race and camshaft journals and
gear mount flange must be smoothed with crocus
cloth moistened in mineral spirits. This is to be
accomplished while the shaft is rotated in a lathe
at approximately 100 RPM. All gum (varnish)
deposits must be removed to permit reliable
magnetic indications during magnetic particle
inspection. Flush the internal portion of the
crankshaft using mineral spirit solvent. Insure that
all threads, oil passages and recesses are clean and
free of debris. Clean the counterweights using
mineral spirits.
WARNING
Do not pressure blast counterweights with an
abrasive media. Blasting will remove surface
hardening.
3. Remove the connecting rod bolts and nuts but do
not discard at this time. All areas of the
connecting rods must be degreased by brushing or
spraying with mineral spirit solvent. Insure all
bolt holes, oil passages and recesses are clean and
free of debris. All gum (varnish) deposits must be
removed to permit reliable magnetic indications
during magnetic particle inspection.
4. Clean gears that have bushings using mineral
spirit solvent and a brass wire brush. Gears with
bushings must not be cleaned using alkaline
solutions. Gears that do not have bushings can be
cleaned using mineral spirit solvent or by
immersion in a alkaline stripping bath, if mineral
spirit solvent is not effective. After cleaning with
alkaline solution, the gears must be sprayed with
steam removing all traces of alkaline. After steam
rinsing the gears must be thoroughly flushed with
mineral spirit solvent.
Chapter 18
CAUTION…
Alkaline cleaning solutions will cause corrosion to
metals if not completely removed.
WARNING
Do not pressure blast gears with an abrasive
media. Blasting will remove surface
hardening.
18-4
ENGINE DRIVE TRAIN
INSPECTION
burning. Inspect the gear bolt holes for distorted
or stripped threads. Check oil passages for
obstructions and loose oil tubes. Check the gear
dowel for a tight fit. Inspect the oil control plug
for presence, obstructed oil hole and tight fit.
Visually inspect the entire crankshaft for rust and
pitting. Crankshafts exhibiting any of the above
indications must be repaired or replaced.
Crankshaft repairs must be performed under
carefully controlled conditions using an approved
procedure and process which meets the
requirements of the applicable federal aviation
regulations.
WARNING
WARNING
Use only crankshafts that are manufactured
from VAR forgings identified by the letters
VAR forged into a crankshaft cheek.
VISUAL INSPECTION
The crankshaft, camshaft, connecting rods and
associated engine drive train components must be
visually inspected in accordance with the instructions
in Section 5-8, "Visual Inspection," and the following
special instructions.
1. Visually inspect the camshaft journals and lobes
using a 10X magnifying glass. Inspect the
camshaft journals and lobes for scoring, pitting,
corrosion and any indications of wear. Camshafts
exhibiting scoring pitting, corrosion or wear
indications must be repaired or discarded. Inspect
the camshaft gear flange for nicks, peening and
other irregularities. The flange must be smooth to
align gear. Inspect the camshaft gear flange bolt
holes for distorted or stripped threads. Camshaft
repairs must be must be performed under
carefully controlled conditions using an approved
procedure and process which meets the
requirements of the applicable federal aviation
regulations.
2. Using a Borrough's 8087A polishing tool or
equivalent rotate the crankshaft in a lathe and
polish the mains and crankpins to a finish of 8 Ra
maximum. Inspect the finish using a profilometer.
Dimensionally inspect the crankshaft mains and
crankpins for required specified size.
3. Visually inspect the crankshaft main journals,
crank pins and oil seal area for scoring and
The counterweights and crankshaft must not
be punch marked or scribed for location
identification. Use tagging or ink methods to
identify.
4. Visually inspect counterweights for cracks, nicks,
evidence of contact between bottom of
counterweight and crankshaft. Counterweights
exhibiting these indications must be discarded.
5. Inspect the connecting rod and rod cap for
matching position numbers stamped on the bolt
boss. Discard any connecting rod and cap
assemblies that do not have matching numbers.
Inspect the connecting rod and cap for cracks,
bending, twisting, galling, mechanical damage
and discoloration (bluing). Inspect the connecting
rod and cap parting surface for fretting, rub or any
mechanical damage. Discard connecting rods
with bolt holes that exhibit raised nicks, burrs or
mechanical damage. Also inspect the bolt hole
dowel area for fretting. Discard connecting rods
with cracks, bending, twisting, galling or
mechanical damage. Discard any rod assembly
exhibiting fretting or rub on the parting surfaces
or the dowel area of the bolt holes. Discard any
rod assembly exhibiting corrosion etching, rust or
rust pitting.
NOTE…
No rework is permitted to connecting rod and end cap
parting surface.
Remove any sharp edge on the bolt holes at the
parting surfaces with crocus cloth. Inspect the
sides of the connecting rod and cap for any
indications of hard contact with the crankshaft. If
18-3
Chapter 18
hard contact damage has occurred, discard the
connecting rod and cap and inspect the
corresponding area of the crankshaft. If damage
has occurred to the crankshaft it must also be
discarded. Inspect the complete outside area of
the connecting rod and cap assembly for any
damage to the shot peened surface. Discard any
connecting rod and cap assembly exhibiting
damage to the shot peened surface.
6. Using a 10X magnifying glass, visually inspect
the crankshaft gear and idler gear drive gear teeth
for signs of overheating and wear. Normal wear
produces a fine polish on the tooth thrust faces.
Gears that have alteration of the tooth profiles,
score marks, pitting or galling must be discarded.
See Figure 8-1, “Gear Tooth Wear,” for
acceptable and unacceptable gear tooth wear.
CRANKSHAFT ULTRASONIC INSPECTION
The crankshaft must be ultrasonic inspected by a
certified technician in accordance with Section 5-11.
MAGNETIC PARTICLE INSPECTION
The crankshaft, counterweights, camshaft, crankshaft
gears, camshaft gear, idler gear and governor drive
gear must be magnetic particle inspected by a certfied
technician in accordance with the instructions in
Section 5-9, "Magnetic Particle Inspection."
Clean the connecting rods, caps, bolts and nuts with
solvent and blow dry. Inspect the bolt and nut threads
for damage. Do not assemble connecting rods and
caps with damaged bolts or nuts. Lubricate the
connecting rod bolt and nut threads using clean 50
weight aviation engine oil. Assemble the connecting
rod and cap as follows:
Align the matching numbers on the connecting rod
and cap and hand press the new bolts into the
connecting rod. Do not force bolts through the cap or
rod bolt holes. The connecting rod and cap must be
completely seated and both bolt heads must be
completely seated against the connecting rod cap
seats. Any connecting rod assembly requiring more
than hand pressure to seat the connecting rod, caps
and bolts must be discarded. Install the nuts finger
tight. On assemblies using the 530213 bolts and
626140 nuts, torque the nuts to 400-475 inch pounds.
On assemblies using the 654693 bolts and 654487
nuts, torque the nuts to 490-510 inch pounds.
Magnetic particle inspect all connecting rod and cap
assemblies in accordance with the instructions in
Section 5-9, "Magnetic Particle Inspection."
Connecting rods exhibiting cracks or indications of
cracks must be discarded. Leave the connecting rods
and caps assembled and torqued for bushing
replacement.
NOTE…
Crankshafts, counterweights, camshafts, crankshaft
gears, camshaft gears, idler gears or governor drive
gears exhibiting cracks must be discarded.
18-4
The standard magnetic particle inspection procedure
found in the latest revision of ASTM Standards on
nondestructive testing describes the method of
magnetization, inspection and demagnetization.
Chapter 18
DIMENSIONAL INSPECTION
The following new parts limits must be used for dimensional inspection. Components that do not meet the
following specifications must be discarded.
All components must be thoroughly cleaned and air dried prior to dimensional inspection.
Ref.
No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Description
CRANKSHAFT
Crankshaft in main bearings............................................................Diameter:
Crankshaft in thrust bearing ................................................... End Clearance:
Camshaft journals in crankcase.......................................................Diameter:
Camshaft in crankcase............................................................ End Clearance:
 Crankpins...........................................................................Out-of-Round:
 Main journals.....................................................................Out-of-Round:
 Rear & Intermediate Journals......................................................Diameter:
 Crankshaft Thrust Journal ...........................................................Diameter:
Crankpins.........................................................................................Diameter:
Crankshaft run-out at center main journals (shaft supported at thrust and rear
journals) full indicator reading :
Taper over crankshaft journal width .............................................................. :
Crankshaft run-out at propeller flange (when supported at front and rear
main journals) full indicator reading.............................................................. :
Damper pin bushing in hanger blade bore .....................................Diameter:
Damper pin bushing in counterweight ............................................Diameter:
Damper pin in counterweight................................................. End Clearance:
Damper pin ......................................................................................... Length:
Crankshaft gear on crankshaft.........................................................Diameter:
Counterweight on hanger blade ............................................. Side Clearance:
Damper pin
643626-110......................................................................................Diameter:
643626-111......................................................................................Diameter:
CAMSHAFT
Camshaft run-out at center journals (shaft support at end journals)
full indicator reading ...................................................................................... :
Camshaft gear on camshaft flange ..................................................Diameter:
Governor drive gear on camshaft....................................................Diameter:
CONNECTING ROD
Connecting rod bearing on crankpin...............................................Diameter:
Connecting rod bolt in connecting rod............................................Diameter:
Connecting rod bearing side clearance .................................. Side Clearance:
Piston pin in connecting rod bushing..............................................Diameter:
GEAR BACKLASH
Crankshaft gear-to-camshaft gear ...................................................Backlash:
New Parts
Min.
Max.
0.001L
0.006L
0.001L
0.005L
0.0000
0.0000
2.373
2.2475
1.936
0.004L
0.018L
0.003L
0.012L
0.0005
0.0005
2.374
2.2485
1.937
0.000
0.000
0.0000
0.0150
0.0005
0.0050
0.0015T
0.001T
0.011L
0.8190
.0000
0.004
0.0030T
0.0025T
0.037L
0.821
0.0025T
0.014
.498
.552
.499
.553
0.0000
0.0010
0.0005T
0.0002L
0.0015L
0.002L
0.0005L
0.0005L
0.0056
0.0014L
0.003L
0.0023L
0.008
0.0021L
0.006
0.009
 If crankshaft is worn beyond these limits it may be repaired by grinding crankpins and journals to 0.010" under
new shaft limits and re-nitriding. Crankshaft machining may be accomplished by a repair facility certified for
specialized crankshaft repairs.
18-5
Chapter 18
During dimensional inspection the camshaft and
crankshaft must be mounted on matched vee blocks
supporting the front and rear main journals. The vee
blocks must be mounted on a surface plate. Rotate the
shafts under a dial indicator placed on the center main
journal to detect bending (runout). Rotate the
crankshaft prop flange under a dial indicator to detect
bending (runout). See items (10, 11,19) of Figure
18-1, "Crankshaft and Camshaft Fits and Limits," for
camshaft and crankshaft runout tolerances.
FIGURE 18-1. CRANKSHAFT, CAMSHAFT AND CONNECTING ROD FITS AND LIMITS
18-6
Chapter 18
DIMENSIONAL INSPECTION (continued)
The connecting rod piston pin bushing alignment
must be checked with the crank pin end bearing bore.
Make alignment measurements using a push fit arbor
for the bushing bore (piston pin end) and another for
the bearing seat (crank pin end). The arbors must be
eight inches long. A surface plate, two matched vee
blocks, and two blocks of ground flat steel stock of
equal height are required. To measure twist, insert the
arbors into the rod bores. Then place the big end arbor
(crank pin end) in the vee blocks on the surface plate.
Place the ground steel blocks under the
ends of the bushing arbor (piston pin end) a measured
distance apart. Use a leaf type feeler gage to detect
any clearance under the arbor ends. This divided by
the separation of the blocks in inches will give the
twist per inch of length. To measure bushing and
bearing convergence mount a dial indicator on a
surface gage and swing the rod around the crank pin
end arbor to the vertical position against a firm stop.
Pass the indicator over the bushing arbor on both
sides of the connecting rod at points an exact number
of inches apart. For exact parallelism the two
measurements must be the same. See Figure 18-2,
"Connecting Rod Fits And Limits."
18-7
Chapter 18
FIGURE 18-2. CONNECTING ROD FITS AND LIMITS
18-8
Chapter 18
NEW PARTS DIMENSIONS
Part Name
Crankshaft Assembly
Camshaft
Connecting Rod
Feature
Rear and Intermediate Journals
Thrust journal
Crankpins
Crankshaft Counterweight Hanger Blade Bushing Bore
Main Journals
Bushing Bore Diameter
Bushing Center to Crank Pin Center
18-5
ENGINE DRIVE TRAIN
REPAIR AND REPLACEMENT
1. Any engine drive train component found to be
worn beyond new parts limits or failing to meet
the inspection criteria in Section 18-4 must be
replaced 100% unless repair is possible with the
following instructions:
2. The crankshaft can be repaired by grinding crank
pins and journals to 0.010" under new shaft limits
and re-nitriding. Crankshaft machining may be
accomplished by a repair facility certified for
specialized crankshaft repairs.
NOTE…
Reground crankshafts must be re-nitrided.
3. Do not attempt to remove scoring or indications
of overheating which render the crankshaft
unserviceable.
4. The crankshaft hanger blade and counterweight
bushings must be replaced 100% at engine
overhaul regardless of condition. Crankshaft
hanger blade bushing replacement must be
performed using the specified procedure and the
following special tool:
New Dimension
(inches)
2.373 - 2.374
2.2475 - 2.2485
1.936 - 1.937
815 - .816
1.3725 - 1.3735
1.0000 - 1.0005
6.3730 - 6.3770
a. Borrough's 8077A Crankshaft Hanger Blade
Bushing Removal/Installation Set or
equivalent.
WARNING
Removing and replacing bushings with
makeshift tools and methods may result in
irreparable damage to the crankshaft and
crankshaft malfunction.
CRANKSHAFT COUNTERWEIGHT HANGER
BLADE BUSHING REMOVAL
Using the specified tool remove the crankshaft
counterweight hanger blade bushings.
CRANKSHAFT COUNTERWEIGHT HANGER
BLADE BUSHING HOLE INSPECTION
After removal of the crankshaft counterweight hanger
blade bushings measure the inside diameter of the
bushing holes. The replacement bushings must have
an interference fit of .0015 to .0035 inch into the
bushing holes. The bushing holes must be smooth.
Crankshafts with worn, pitted, fretted or out of round
bushing holes must be discarded.
18-9
Chapter 18
FIGURE 18-3. CRANKSHAFT HANGER BLADE BUSHING REPLACEMENT
CRANKSHAFT COUNTERWEIGHT HANGER
BLADE BUSHING INSTALLATION
After serviceability of crankshaft has been determined
new bushings must be installed in the crankshaft
counterweight hanger blades. Using the same tools
that were used for bushing removal install the new
bushings. The new bushings must be installed in
accordance with the specifications in Figure 18-3,
"Crankshaft Hanger Blade Bushing Replacement."
Replacement bushings are available in standard size
only.
18-10
NOTE…
After installation of new bushings the crankshaft
counterweight hanger blades must be magnetic
particle inspected in accordance with Section 5-9,
"Magnetic Particle inspection." Discard crankshafts
with cracked counterweight hanger blades.
No finishing operation is required. The new installed
bushings are made to final dimensions.
Chapter 18
5. The counterweight bushings must be replaced
100% at engine overhaul regardless of condition.
The bushing replacement must be performed
using the specified procedure and the following
special tools:
a. Borrough's 8077C Counterweight Bushing
Removal/Installation Fixture or equivalent.
b. Arbor Press.
WARNING
Removing and replacing bushings with
makeshift tools and methods may result in
irreparable damage to the counterweight and
counterweight, crankshaft malfunction.
COUNTERWEIGHT BUSHING REMOVAL
Using the specified tools remove the counterweight
bushings.
COUNTERWEIGHT BUSHING HOLE
INSPECTION
After removal of the counterweight bushings measure
the inside diameter of the bushing holes. The
replacement bushings must have an interference fit of
.0015 to .0035 inch into the bushing bores. The
bushing holes must be smooth. Counterweights with
worn, pitted, fretted or out of round bushing holes
must be discarded. Carefully inspect the
counterweight counterbores for signs of wear in the
wall that retains the counterweight pin retaining
plates. The area referred to is immediately adjacent to
the inside edge of the retaining ring groove. It may
appear as an additional step and/or a taper of the hole
into the retaining ring groove. If any wear is evident
the counterweight must be discarded. See Figure 18-4,
"Counterweight Inspection, Repair and Installation."
If no plate wear is evident, check the retaining ring
groove in each hole for distorted width, depth or other
types of wear patterns which can affect the seating of
the retaining ring. Any worn condition that may affect
retaining ring seating will require replacement of the
counterweight. Crankshaft counterweights are
matched in pairs with a maximum weight variation of
two
grams,
and
the
complete
crankshaft/counterweight assembly is dynamically
balanced. As a result, if either counterweight is
damaged, a matched pair must be procured and
replaced on that cheek.
COUNTERWEIGHT BUSHING
INSTALLATION
After serviceability of the counterweights has been
determined, new bushings must be installed in the
counterweight assemblies. Using the same tools that
were used for bushing removal, install the new
bushings. The new bushings must be installed into the
same positions as the original bushings. Replacement
bushings are available in standard size only.
18-11
Chapter 18
FIGURE 18-4. COUNTERWEIGHT INSPECTION, REPAIR AND INSTALLATION
NOTE…
After installation of new bushings the counterweights
must be magnetic particle inspected by a certified
technician in accordance with Section 5-9, "Magnetic
18-12
Particle inspection." No finishing operation is
required. The new installed bushings are made to final
dimensions.
Chapter 18
FIGURE 18-5. OIL CONTROL PLUG INSTALLATION TOOL
6. Loose or leaking crankshaft oil control plugs must
be replaced. The oil control plug replacement
must be performed using the specified procedure
and the following special tools:
a. A .4375 - 20 diameter bolt approximately
eight inches long with .4375 - 20 NF
threads.
b. An installation tool conforming to the
specifications shown in Figure 18-5, "Oil
Control Plug Installation Tool."
c. Two inch Merrit Wheel.
d. A leak test fixture conforming with the
specifications shown in Figure 18-6, "Oil
Control Plug Leak Test Fixture."
CRANKSHAFT OIL CONTROL PLUG
REMOVAL
Remove crankshaft oil control plug using a .4375 - 20
diameter bolt approximately eight inches long with
.4375 - 20 NF threads and a slide hammer.
OIL CONTROL PLUG HOLE CLEANING
Inspect the inside diameter of the crankshaft for rust
and rust pits. Discard crankshafts with rust or rust pits.
The inside diameter of the crankshaft must be clean
and free of any sludge residue prior to new plug
installation. Clean crankshaft inside diameter using a
pneumatic drill and a two inch Merrit Wheel.
WARNING
Removing and replacing the crankshaft oil
control plug with makeshift tools and methods
may result in irreparable damage to the
crankshaft and crankshaft malfunction.
18-13
Chapter 18
FIGURE 18-6. OIL CONTROL PLUG LEAK TEST FIXTURE
18-14
Chapter 18
OIL CONTROL PLUG INSTALLATION
Using an air impact tool and the special oil control
plug installation tool, carefully drive in the new oil
control plug.
WARNING
The use of makeshift tools not conforming
with the specifications shown in Figure 18-5,
"Oil Control Plug Installation Tool," may
cause damage to oil control plug or crankshaft
during installation. The 2.375 inch diameter
collar at the rear of installation tool prevents
driving oil control plug beyond the specified
depth of 5.31 inches.
OIL CONTROL PLUG INSPECTION
Using the special leak test fixture shown on previous
page and a "C" clamp that has its spindle and foot
protected by neoprene rubber pads, pressure test the
crankshaft. See Figure 18-7, "Crankshaft Leak Test."
The oil control plug must maintain 60 PSI
minimum air pressure.
FIGURE 18-7. CRANKSHAFT LEAK TEST
18-15
Chapter 18
7. After all crankshaft repairs have been completed,
use a strip of 180 grit emery cloth approximately
1/2 inch wide and apply a helix to the crankshaft
as shown in Figure 18-8, "Helix Pattern
Application." Apply helix to approximately 1/4 of
the surface indicated at a time. The pattern is
applied by stroking the cloth outward toward the
propeller flange in the direction of rotation, CCW
towards you using maximum hand pressure,
which will result in a 30° pattern as shown. After
doing the first portion, rotate the crankshaft so
that the next portion is visible. Apply the same
pattern again and continue completely around
crankshaft in this manner. The helix is applied to
insure proper seating of the crankshaft oil seal.
After helix application the crankshaft must be
re-cleaned. After the helix has been applied the
helix area must be tin plated. See Section 18-3,
"Engine Drive Train Cleaning."
FIGURE 18-8. HELIX PATTERN APPLICATION
9. All connecting rod piston pin bushings must be
replaced 100% at overhaul. The connecting rod
piston pin bushing replacement must be
performed using the specified procedure and the
following special tools:
a. Arbor press.
b. Borrough's 8098 Connecting Rod Bushing
Removal/Installation Set or equivalent.
c. Borrough's 8111A Connecting Rod Reaming
and Alignment Fixture or equivalent.
d. High Speed Reamer of the correct size.
e. Borrough's 8042C Adapter Kit or equivalent.
f. Vertical Mill or equivalent capable of
maintaining 1750 RPM.
g. Federal Dimension Air Gage with a 1.00025
Setting Ring and 1.00025 Air Plug or
equivalent.
18-16
h. Profilometer.
WARNING
Removing and replacing the connecting rod
piston pin bushings with makeshift tools and
methods may result in irreparable damage to
the connecting rods and connecting
rod/crankshaft malfunction.
CONNECTING ROD BUSHING REMOVAL
Press out old bushing using connecting rod bushing
removal/installation set and an arbor press. No nicks,
gouges or other damage is permissible on the bore
after bushing removal. Connecting rods exhibiting
any of the above must be discarded.
Chapter 18
CONNECTING ROD BUSHING
INSTALLATION
Make sure that the rod bore is smooth. Dip the new
bushing in clean 50 wt. aviation engine oil before
placing it in position and locate the split as shown in
Figure 18-2, "Connecting Rod Fits And Limits."
Install new bushing using connecting rod
removal/installation set and an arbor press.
CONNECTING ROD BUSHING FINISHING
Bore the new bushing to the specified diameter of
1.000 - 1.0005 inches.
CONNECTING ROD INSPECTION
Using a profilometer inspect the piston pin bushing
finish. The required surface finish is 32 RMS.
Because of the close tolerances required, the replaced
bushings must be inspected using an air gage with
correct size air plug and setting ring. After connecting
rod bushing inspection, the connecting rod bushing
alignment with the big end bearing seat must be
inspected in accordance with Section 18-4,
"Dimensional Inspection."
CAUTION…
In order to assure good dynamic balance, connecting
rod assemblies are selected in pairs with a maximum
weight variation of 1/2 ounce in opposite bays.
Therefore, rods are supplied in matched sets only.
WARNING
Never remove material from any connecting
rod.
9. Insure that all engine drive train associated parts
listed in Section 5-6, "100% Replacement Parts,"
have been replaced.
18-6 ENGINE DRIVE TRAIN
SUBASSEMBLY
WARNING
Use only crankshafts that are manufactured
from VAR forgings identified by the letters
VAR forged into a crankshaft cheek.
NOTE…
All engine drive train components must be clean and
free of debris before assembly.
NOTE…
Before assembly the crankshaft and camshaft must be
checked for remaining magnetism from inspection
procedures. If found demagnetize.
NOTE…
The standard magnetic particle inspection procedure
found in the latest revision of ASTM standards on
nondestructive testing describes the method of
magnetization, inspection and demagnetization.
1. See Figure 6-18, "Camshaft Assembly." Install
the camshaft in a suitable holding fixture. Using a
rawhide mallet tap a new woodruff key (4) into
camshaft groove and tap governor drive gear (5)
onto camshaft.
2. Install gear (2) on camshaft (1). The gear bolt
holes are off-set to assure proper positioning for
timing. Install four new bolts (3) and torque to
240-260 inch pounds torque. Safety wire bolt
heads in accordance with Section 4-2, "Lockwire
Procedure." After assembly coat camshaft with
clean 50 wt. aviation engine oil.
3. See Figure 6-19, "Crankshaft Assembly." Place
the crankshaft on a bench with a notched wood
block under front and rear journals. Attach one
counterweight (3) to crank cheek No. 2 hanger
blade with two new pins (5). Install new plates
and retaining rings (10, 11) with sharp edge
outboard. Attach one counterweight (3) to the
opposite crank cheek No. 2 hanger blade with two
new pins (6). Install new plates and retaining
rings (10, 11) with sharp edge outboard. Pins
with the same part number and dash number must
be installed in each counterweight.
CAUTION…
The retaining rings, plates and pins must be installed
as shown in Figure 18-4, "Counterweight Inspection,
Repair and Installation."
Chapter 18
The counterweight plates have a small extruded
point which provides an interference fit of .001 to
18-17
.007. During installation, check the counterweight
plates for an actual interference fit in the bushing
bore. An interference fit is required.
WARNING
Do not use plates that have a loose fit.
NOTE…
Counterweight pins are identified by dash numbers
stamped on one end. Because the counterweight order
is controlled by the pin diameter it is imperative only
the correct pin, properly identified, be used. The 4-1/2
order 643626-110 pin has an O.D. of .498-.499. The
6th order 643626-111 pin has an O.D. of .552-.553.
WARNING
Do not exceed ten minutes at 350°F during
crankshaft gear heating process. Do not use a
torch to heat the crankshaft gear. The heating
process must be performed using uniform
heating methods only.
4. Heat crankshaft gear (14) to 300°F for 5 to 10
minutes. Use thick gloves to handle gear. Align
gear dowel hole with crankshaft dowel and install
gear on crankshaft. Attach crankshaft gear (14) to
crankshaft using four new bolts (15). Torque bolts
to 240-260 inch pounds in a criss-cross pattern.
Install lockwire on bolts (15) in accordance with
Section 4-2, "Lockwire Procedure."
5. Original connecting rods have a position number
stamped on the end cap and rod bolt boss. New
18-18
connecting rods must have a position number, 1
through 6 as applicable, vibro etched
in the
Chapter
18
location shown in Figure 18-9, " Connecting Rod
Position Number." See Figure 6-19. Remove the
bolts and nuts from the connecting rods and
discard. Place a sheet of crocus cloth on a flat
surface plate and dampen with solvent. Lightly
rub the parting surface of the rod, cap and rod
across the crocus cloth to remove any burrs or
nicks. Inspect the parting surfaces, bolt holes and
bolt hole edges to insure there are no nicks burrs
or sharp edges. Clean rods, caps, bolts and nuts
thoroughly, blow dry and place on a clean cloth.
Clean the new bearing inserts in solvent and blow
dry. Inspect the bearings for damage and insure
each bearing is the correct size and part number
for the connecting rod/crankshaft to be used.
Install a new bearing in each rod cap and rod.
Insure that the bearing ends project the same
distance even with the parting surface and that
they are properly seated. Closely examine for and
remove any metal that may have shaved from the
bearing back onto the parting surface during
installation. Coat the rod bolt completely with
clean 50 weight aviation engine oil. Align the
matching numbers on the connecting rod and cap
and hand press the new bolts into the connecting
rod. Do not force bolts through the cap or rod bolt
holes. The connecting rod and cap must be
completely seated and both bolt heads must be
completely seated against the connecting rod cap
seats. Any connecting rod assembly requiring
more than hand pressure to seat the connecting
rod, caps and bolts must be discarded. Remove
the connecting bolts and separate the connecting
rod and cap Inspect each connecting rod
assembly for correct fit.
Chapter 18
FIGURE 18-9. CONNECTING ROD POSITION NUMBER
4. Insure that the new bearings are properly seated.
Using clean 50 wt. aviation oil, lubricate and
install each rod, cap and bearing assembly at the
correct position on the crankshaft. Install the
connecting rod and cap with their numbers on top
when odd number rods are extended to the right
and even number rods are to the left viewing
crankshaft from the rear (gear end) forward.
Lubricate the new connecting rod bolt and nut
threads using clean 50 weight aviation engine oil.
Secure rods and caps using new special bolts and
nuts (20 & 21). On assemblies using the 530213
bolts and 626140 nuts, torque the nuts (21) to
400-475 inch pounds. On assemblies using the
654693 bolts and 654487 nuts, torque the nuts
(21) to 490-510 inch pounds. On assemblies using
the 530213 bolts and 626140 nuts, install cotter
pins (23) and secure in accordance with Figure
4-5 "Connecting Rod Cotter Pin Installation."
7. Remove spring (17) from oil seal (16). Unhook
spring ends. Place new spring around crankshaft
in oil seal area and re-hook ends. Install new split
oil seal (16) over the crankshaft. After oil seal is
on shaft, press the reinforcing spring into the oil
seal recess by moving fingers in both directions
from split. Insure spring is in deepest part of
recess all the way around.
8. Store engine drive train components in a clean
protected area until final engine assembly.
18-19
Chapter 18
INTENTIONALLY
LEFT
BLANK
18-20
Chapter 19
CHAPTER 19
FINAL ASSEMBLY
SECTION
19-1
19-2
19-3
19-4
19-5
19-6
19-7
19-8
19-9
19-10
19-11
19-12
19-13
19-14
19-15
19-16
19-17
19-18
19-19
FIGURE
19-1
19-2
19-3
19-4
19-5
19-6
19-7
19-8
19-9
19-10
19-11
19-12
19-13
19-14
19-15
PAGE
General ....................................................................19-3
Crankcase ................................................................19-3
Crankcase Sealant and Threading Procedure .........19-5
Crankcase Through Bolt Installation and
Torquing Sequence .................................................19-6
Oil Sump ................................................................19-12
Accessory Case ......................................................19-12
Compressor Mounting Components, Starter
Adapter And Starter Motor TSI0-360-RB .............19-14
Starter Adapter And Starter Motor
LTSI0-360-RB ........................................................19-18
Alternator Assembly ...............................................19-18
Valve Mechanism ..................................................19-18
Cylinder Baffling ....................................................19-20
Cylinder Drain Assemblies.....................................19-20
Exhaust System ......................................................19-21
Induction System ...................................................19-22
Fuel Injection System ............................................19-23
Engine Timing Position Procedure ........................19-24
Magneto Timing and Installation On Engine.........19-27
Ignition Harness Pre- Installation Instructions .......19-28
Ignition Harness Installation...................................19-29
PAGE
Crankcase and Shafts Assembled on Stand............19-4
Alignment of Timing Marks...................................19-4
Crankcase Sealant And Threading Procedure .......19-6
O-Ring Installation Tool.........................................19-7
Crankshaft Oil Seal Installed ..................................19-8
Right Side View of Crankcase on Stand ...............19-8
Installing Number Five Cylinder............................19-10
Torquing Cylinder Base Nut...................................19-10
Torquing Sequence .................................................19-11
Oil Sump Torquing Sequence.................................19-12
General Bottom View ............................................19-12
Accessory Case Torquing Sequence ......................19-13
General Accessory Case and
Accessories Installed...............................................19-14
Starter And Freon Compressor Brackets................19-16
Compressor Bracket Alignment .............................19-17
19-1
Chapter 19
FIGURE
19-16
19-17
19-18
19-19
19-20
19-21
19-22
19-23
19-24
19-25
19-26
TABLE
19-1
19-2
PAGE
Rocker Arm to Rotocoil Clearance ........................ 19-19
Checking Rocker Arm Clearance........................... 19-20
General Installing Pushrod Housing ...................... 19-20
Multi-Segment "V" Band Clamp ........................... 19-21
Timing Position Step One ...................................... 19-24
Timing Position Step Two .................................. 19-25
Timing Position Step Three ................................ 19-25
Timing Position Step Four .................................. 19-26
Timing Position Step Five................................... 19-26
Coating Insulating Sleeve ................................... 19-28
Ignition Wiring Diagram..................................... 19-30
PAGE
Coupling Nut Torque Values .............................. 19-29
Chapter 19
19-1 GENERAL
WARNING
Use only parts meeting the engine type design.
Apply clean 50 weight aviation engine oil liberally to
all bare steel surfaces, journals, bearings and bushings
before and after installation, except where special
lubricants are required. See Chapter 3, "Table of
Sealants and Lubricants."
During assembly the mechanic must measure
clearances of running parts as they are installed and
compare with clearances listed in Fits and Limits of
the applicable system or component section. During
engine overhaul use only NEW PARTS LIMITS. See
Section 6-16, "New Parts and Service Limits." Also
TCM requires certain parts be replaced 100% at
overhaul. See Section 6-6, "100% Replacement
Parts."
Engine assembly must be performed in a clean dust
free environment. All engine openings must be
covered as soon as possible to prevent admittance of
debris or small parts.
19-2 CRANKCASE (See figures
as indicated in paragraphs.)
NOTE…
See Chapter 2 for lubricant specifications and
suppliers.
1. Uncover crankcase halves. Using clean 50 weight
aviation engine oil, thoroughly coat all crankcase
camshaft bearing surfaces, prop governor gear
bearing surface, starter shaft gear bushing and
idler gear bushing. The crankshaft bearing saddles
must be dry prior to crankshaft bearing
installation do not coat them with oil. Chapter 19
2. See Figure 6-17. Using new o-ring (23), install
engine mount bracket (38) and prop cable bracket
(17) on 2-4-6 crankcase half. Secure brackets
using attaching hardware (20, 21, 22). Using new
o-rings (23), install engine and oil cooler mount
bracket (36) on 2-4-6 crankcase half. Secure
bracket using attaching hardware (20, 21, 22).
Using new o-ring (23), install engine mount
bracket (37) on 1-3-5 crankcase half. Secure
bracket using attaching hardware (20, 21, 22).
Install engine mount bracket (35) and
turbocharger bracket (48) on 1-3-5 crankcase half.
Secure brackets using attaching hardware (20,
22). Snug but do not torque nuts (22) at this time.
3. Install left crankcase half on engine stand open
side up. Lay right crankcase half on bench open
side up. Using clean 50 weight aviation engine
oil, thoroughly lubricate all surfaces that were
lubricated on the right crankcase half. Do not
lubricate the crankshaft bearing saddles. See
Figure 17-3, "Crankcase Stud Setting Heights,"
install Bushing (2) and align with dowel in
position shown on 1-3-5 case half.
4. See Figure 6-19, "Crankshaft Assembly." Using a
piece of clean smooth bar stock, roll new
packings (12) into both new bearing halves (11).
Insure that the packings seat in bearing halves
properly. Trim the new packing ends flush to the
bearing edge with a razor. Install crankshaft
bearings (10, 11) in crankcase crankshaft bearing
saddles. Apply clean 50 weight aviation engine
oil to thrust washer lands in crankcase to prevent
thrust washer halves from falling out during final
assembly. Install thrust washer halves (13). Insure
that the bearing and thrust washer ends project
equally and are properly seated in lands.
Lubricate bearings with clean 50 weight aviation
engine oil.
19-3
Chapter 19
5. Apply a thin coat of Permatex to outside diameter
of crankshaft oil seal. With the aid of an assistant,
lift crankshaft assembly by Number 1 connecting
rod and propeller flange. While assistant is
holding Number 3 connecting rod upward,
carefully lower assembly into its position. Check
to make sure bearings and thrust washers are still
seated properly. Make sure crankshaft oil seal is
properly seated. The oil seal split line must be
positioned so it is at the one o'clock position from
the crankcase splitline. The connecting rod
position numbers, if properly installed, will be
toward the upper case flange. Carefully lay odd
numbered connecting rods on the upper case
flange.
6. See Figure 6-18, "Camshaft Assembly." Using
clean 50 weight aviation engine oil, lubricate and
install camshaft (1) into crankcase. Make sure
timing marks on camshaft and crankshaft align as
gears mesh. Number 1 connecting rod on
crankshaft should be in its fully extended (TDC)
position. Governor driven gear may have to be
turned slightly to allow camshaft to seat in its
bearings properly.
FIGURE 19-1. CRANKCASE AND SHAFTS ASSEMBLED ON STAND
FIGURE 19-2. ALIGNMENT OF TIMING MARKS
19-4
Chapter 19
CAUTION…
If the crankcase has been machined, gear backlashes
must not be less than the specified minimum after
machining.
7. Check camshaft to crankshaft gear backlash and
compare with tolerance in Figure 18-1, "
Crankshaft, Camshaft and Connecting Rod Fits
and Limits." Coat camshaft lobes with Dow
Corning G-N Paste. [Dow Corning® is a
registered trademark of Dow Corning
Corporation.]
8. Measure crankshaft end clearance using a dial
indicator set at zero against the propeller flange.
Crankshaft end clearance must be .006 to .018.
Measure camshaft end clearance at either end of
its rear main bearing. Camshaft end clearance
must be .005 to .012. Measure governor drive
gear backlash it must be .002 to .012.
9. Apply sealants and thread to crankcase halves in
accordance with the instructions in Section 19-3,
"Crankcase Sealant And Threading Procedure."
19-3 CRANKCASE SEALANT
AND THREADING PROCEDURE
1. Use full strength non-thinned Permatex aviation
grade 3D. Shake or mix well before using.
WARNING
Apply thread
illustrated.
and
permatex
only
as
2. Apply Permatex Number 3D to the 2-4-6 case
half. Apply Permatex only in areas where thread
is shown. When applying, use short light brush
strokes until an even thin coat is obtained. The
Permatex should be viscous enough that most of
the brush marks disappear; if not, use a new can
of Aviation Permatex. Allow the Permatex to air
dry to a tacky condition before threading.
3. Apply a thin even coat of TCM Gasket Maker
P/N 646942 to 1-3-5 case half. Apply Gasket
Maker in all areas that will mate with areas where
Permatex was applied on 2-4-6 case half. Gasket
Maker is to be applied sparingly .010 to .020 inch
thick.
Apply grade D silk thread P/N 641543 on 2-4-6
case half only. Apply thread as shown in Figure
19-3. Be sure free ends of thread are covered by
gaskets except at the nose oil seal.
4. Assemble crankcase halves in accordance with
the following paragraphs. Install and torque all
crankcase hardware in proper sequence, in
accordance with Section 19-4 as soon as possible.
5. Stand odd numbered connecting rods straight up.
Have an assistant balance and guide connecting
rods through 1-3-5 case half cylinder openings as
crankshaft assembly is installed.
6. Place the 1-3-5 (right) crankcase half on 2-4-6
(left) case half. Take care to prevent displacement
or damage to the crankshaft oil seal and silk
thread. Insure thrust washer, bearing halves and
starter shaftgear bushing remain in the correct
position.
19-5
Chapter 19
FIGURE 19-3. CRANKCASE SEALANT AND THREADING PROCEDURE
19-4 CRANKCASE THROUGH
BOLT INSTALLATION AND
TORQUING SEQUENCE.
CAUTION…
All studs and through bolts must be lubricated in
accordance with Chapter 2, "Tools, Equipment,
Sealants and Lubricants."
NOTE…
See Figure 6-17, "Crankcase Attaching Parts." See
Figure 19-9, "Torquing Sequence," for crankcase stud
and through bolt hole positions.
19-6
WARNING
Failure to lubricate threads, apply the specific
torque and follow the specific torquing
procedure may result in crankcase bearing
bore damage, crankshaft bearing damage,
crankshaft damage and subsequent engine
malfunction or failure.
Chapter 19
FIGURE 19-4. O-RING INSTALLATION TOOL
1. See Figures 6-17, "Crankcase Attaching Parts and
19-9, "Torquing Sequence." Using an o-ring
installation
tool
conforming
with
the
specifications in Figure 19-4, "O-Ring Installation
Tool," and new o-rings (29), install five 7/16 x
10.48 inch through bolts in positions (1, 4, 10, 13
and 30).
Install one 7/16 x 9.96 inch through bolt in
position (33). Install two 7/16 x 6.80 inch through
bolts in positions (27, 28). Install one 3/8 inch
through bolt (19) in position (38). Install one 3/8
inch through bolt (14) in position (29). Install one
1/4 inch through bolt (13) in position (40). Install
one 3/8 inch through bolt (15) in position (9).
Install one 3/8 inch through bolt (18) in position
(18). Tap through bolts in to a centered position
using a plastic or rawhide mallet. These bolts
align crankcase castings and bearings.
Install two spacers (40) and bracket (39) on 1-3-5
case half through bolts at positions (19, 27, 28).
Install four 7/16 washers (30) and four nuts (28)
in positions (27, 28). Install two 7/16 washers
(30) and two nuts (28) on 2-4-6 case side in
positions (30, 33).
Install two 3/8 washers (20) and two nuts (22) in
positions (38). Install two 3/8 washers (20) and
two nuts (22) in positions (29). Install two 3/8
washers (20) and two nuts (22) in positions (9).
Install two 3/8 washers (20) and two nuts (22) in
positions (18). Install two 1/4 washers (4) and two
nuts (5) in positions (40). Snug but do not torque
nuts (5, 22, 28) at this time. This hardware will
hold crankcase halves and internal mechanism
together during assembly and torquing sequence.
2. Rotate engine stand to place
position as shown in Figure
View of Crankcase On
connecting rods using old
o-rings. See Figure 6-15A,
Support."
engine in upright
19-6, "Right Side
Stand." Support
(clean) cylinder
"Connecting Rod
3. Place brackets and lifting eye in their correct
positions on the crankcase backbone in
accordance with Figure 6-17, "Crankcase
Attaching Parts." Install backbone bolts (1
through 3) with washers (4) and nuts (5) in to hole
positions (41 through 51). Snug but do not
torque nuts (5) at this time.
19-7
Chapter 19
FIGURE 19-5. CRANKSHAFT OIL SEAL INSTALLED
FIGURE 19-6. RIGHT SIDE VIEW OF CRANKCASE ON STAND
19-8
Chapter 19
4. Install the cylinder and piston assemblies in
accordance with the following procedure.
connecting rod and slide the piston pin into
the connecting rod and piston. Using a ring
compressor, compress the number 4 piston
ring and push the cylinder until the number 4
ring is positioned inside the cylinder barrel.
Remove the ring compressor and push the
cylinder assembly against the crankcase
cylinder deck with the stud holes aligned.
NOTE…
See Chapter 2 for lubricant specifications and
suppliers.
WARNING
The improper use of sealants and lubricants
may cause engine malfunction or failure.
a. Verify that all cylinder valve keepers have
been properly installed.
b. Insure that each cylinder has a new cylinder
base packing properly installed as described
in section 16-6. Insure that the cylinder
baffles have been properly installed as
described in section 16-6.
c. Carefully rotate the crankshaft placing the
number 1 and number 2 connecting rods in
their outer most position. Lubricate all
cylinder through bolt and deck stud threads
using clean 50 weight aviation engine oil.
d. Back the number 1 piston pin far enough out
to allow the piston to be installed on the
number 1 connecting rod. Place the number 1
cylinder and piston assembly on the number 1
connecting rod and slide the piston pin into
the connecting rod and piston. Using a ring
compressor, compress the number 4 piston
ring and push the cylinder until the number 4
ring is positioned inside the cylinder barrel.
Remove the ring compressor and push the
cylinder assembly against the crankcase
cylinder deck with the stud holes aligned.
e. Install the cylinder deck and through bolt nuts
but do not torque at this time.
f.
Back the number 2 piston pin far enough out
to allow the piston to be installed on the
number 2 connecting rod. Place the number 2
cylinder and piston assembly on the number 2
g. Install the cylinder deck and through bolt nuts
but do not torque at this time.
h. Carefully rotate the crankshaft placing the
number 3 and number 4 connecting rods in
their outer most position.
i.
Using the same procedure that was used to
install the number 1 and number 2 cylinder
and piston assemblies, install the number 3
and number 4 cylinder and piston assemblies.
j.
Carefully rotate the crankshaft placing the
number 5 and number 6 connecting rods in
their outer most position.
k. Using the same procedure that was used to
install the number 1 and number 2 cylinder
and piston assemblies, install the number 5
and number 6 cylinder and piston assemblies.
l.
Apply Champion® thread lubricant to spark
plugs in accordance with the manufacturer's
instructions. Install gaskets and spark plugs in
cylinder spark plug holes. Do not Torque at
this time.
NOTE…
Have an assistant hold nuts on opposite end of
cylinder through bolts when torquing cylinder
attaching hardware.
19-9
Chapter 19
5. After all cylinders have been installed, using the
sequence shown in Figure 19-9, torque nuts at
positions (1 through 52) to the following
preliminary torques:
NOTE…
Crankcase and cylinder torquing requires two people.
WARNING
The torque values specified for engine
reassembly are for use with clean nuts, bolts
and studs with threads that are free of
damage, distortion and that have been
lubricated with clean 50 weight aviation
engine oil prior to torquing. The torque
wrench used for torquing must be currently
calibrated and traceable to the National
Bureau of Standards. Incorrect through bolt
torque may result in subsequent engine
malfunction and failure.
FIGURE 19-7. INSTALLING NUMBER
FIVE CYLINDER
19-10
FIGURE 19-8. TORQUING CYLINDER
BASE NUT
Chapter 19
CRANKCASE PRELIMINARY TORQUE VALUES
PRELIMINARY TORQUE
inch pounds
300
225
150
225
56
SEQUENCE NUMBER
1, 4, 10, 13, 19, 22, 30B, 33B
2, 3, 5 through 8, 11, 12, 14 through 17 20, 21, 23 through 26, 31, 32, 34
through 37
9, 18, 29, 38
19B, 22B, 27, 28, 30A, 33A
39 through 52
FIGURE 19-9. TORQUING SEQUENCE
NOTE…
Crankcase and cylinder torquing requires two people.
6. Using the sequence shown in Figure 19-9, torque
nuts at positions (1 through 52) to the following
final torques:
CRANKCASE FINAL TORQUE VALUES
FINAL TORQUE
inch pounds
590 - 610
440 - 460
275 - 325
440 - 460
100 - 125
SEQUENCE NUMBER
1, 4, 10, 13, 19, 22, 30B, 33B
2, 3, 5 through 8, 11, 12, 14 through 17 20, 21, 23 through 26, 31, 32, 34
through 37
9, 18, 29, 38
19B, 22B, 27, 28, 30A, 33A
39 through 52
7. See Figure 6-17, "Crankcase Attaching Parts."
Torque remaining engine mount bracket nuts (22)
to 275-325 inch pounds.
8. See Figure 6-16, "Crankcase Associated Parts."
Apply Loctite 271 to screws (6). Apply Loctite
Primer 7471 crankcase oil seal retainer screw
holes. Install crankshaft oil seal retainer plates (5)
and secure with screws (6). Torque screws (6) to
21.0-25.0 inch pounds. Using new gasket (1)
install camshaft cover (2) and secure with
attaching hardware (3, 4). Torque screws (4) to
75-85 inch pounds.
19-11
19-5 OIL SUMP (See Figure
6-13).
1. Apply a thin coat of TCM Gasket Maker 646942
to oil sump flange and bottom crankcase flange.
Install new gasket (1) and oil sump (2) on
crankcase, secure with attaching hardware (4, 5,
6). Do not snug or torque oil sump hardware at
this time. Proceed with accessory case
installation.
FIGURE 19-10. OIL SUMP TORQUING SEQUENCE
19-6 ACCESSORY CASE (See
figures as indicated in paragraphs.)
NOTE…
Insure the accessory case has been properly assembled
in accordance with Section 14-6 and 15-6 prior to
installation on crankcase.
1. See Figures 6-10 and 6-10A. Apply a thin coat of
TCM Gasket Maker 646942 to the rear crankcase
and oil sump flange. In the area of the accessory
case, crankcase and oil sump joint, thicker
application of gasket maker (up to .020 of an
inch) will assist in proper sealing. Apply a thin
coat of TCM Gasket Maker 646942 to accessory
case flange. Lubricate the crankcase/accessory
case stud threads with clean 50 weight aviation
engine oil. Install new accessory case gasket (1)
on crankcase/accessory case studs. Install
accessory case. Secure case using attaching
hardware (32 through 36). Do not torque at this
time.
FIGURE 19-11. GENERAL BOTTOM VIEW
19-1
Chapter 19
Lubricate the accessory case/oil filter adapter stud
threads with clean 50 weight aviation engine oil.
Using new gasket (23) install oil filter adapter
(25). Secure oil filter adapter using attaching
hardware (29, 30, 31). See Figures 6-10 and
6-10A.
See Figure 6-13 for oil sump hardware. See
Figures 6-10 and 6-10A for accessory case
hardware. Using the torque sequences shown in
Figures 19-10, "Oil Sump Torquing Sequence"
and 19-12, "Accessory Case Torquing Sequence,"
first torque the oil sump nuts (6) to 50 inch
pounds preliminary torque. Torque the accessory
case nuts (34), bolts (35) and bolt (36) to 100 inch
pounds preliminary torque. Insure the accessory
case and oil sump pull up to the crankcase evenly.
Using the torque sequences shown in Figures
19-10, "Oil Sump Torquing Sequence" and 19-12,
"Accessory Case Torquing Sequence," torque the
oil sump nuts (6) to 90-110 inch pounds final
torque and torque the accessory case nuts (34),
bolts (35) and bolt (36) to 180-220 inch pounds
final torque.
Install new gasket (16) and tach drive adapter
cover (17) on accessory case studs. Secure using
attaching hardware (18, 19, 20). Torque nuts (20)
to 90-100 inch pounds.
2. See Figures 6-10 and 6-10A. Install fitting (27) in
oil filter adapter. Sparingly apply Dow Corning®
No. 4 to the oil filter rubber seal. Fill new oil filter
with clean Type ll corrosion preventative mineral
oil conforming with MIL-C-6529. Install new oil
filter assembly on adapter and torque to 550-520
inch pounds. Safety wire oil filter assembly in
accordance with Section 4-2, "Lockwire
Procedure."
3. See Figure 6-13. Install new gasket (8) and plug
(7) in oil sump. Torque plug (7) to 185-215 inch
pounds torque. Safety wire plug (7) in accordance
with Section 4-2, "Lockwire Procedure."
4. See Figure 6-16. Install new clamps (11, 15) on
oil gauge housing (9) and accessory case oil filler
neck. Secure the clamps using screw (14), washer
(12) and new lock nut (13). Torque lock nut (13)
to 17-22 inch pounds.
FIGURE 19-12. ACCESSORY CASE TORQUING SEQUENCE
19-13
Chapter 19
FIGURE 19-13. GENERAL ACCESSORY CASE AND ACCESSORIES INSTALLED
19-7 COMPRESSOR
MOUNTING COMPONENTS,
STARTER ADAPTER AND
STARTER MOTOR TSI0-360-RB
(See Figure 6-5.)
1. Apply Permatex Number 3D to the accessory
case/starter adapter mount flange. When applying,
use short light brush strokes until an even thin
coat is obtained. The Permatex should be viscous
enough that most of the brush marks disappear; if
not, use a new can of Aviation Permatex. Allow
the Permatex to air dry to a tacky condition before
threading.
2. Apply grade D silk thread P/N 641543 between
bolt holes and cavity opening and around dowel
holes. Be sure that the silk thread is positioned
correctly and the thread ends are crossed in the
adapter to accessory case contact area.
19-14
3. Apply a thin coat of TCM Gasket Maker 646942
to the starter adapter mating surface only.
CAUTION…
Sealant must be applied sparingly to prevent
contamination of the engine oil system.
4. Lubricate starter shaftgear teeth with clean 50
weight aviation engine oil and mesh with
crankshaft gear teeth as adapter is placed in
position. Seat adapter against threaded mount
flange. Apply Loctite Pipe Sealant with Teflon P
S/T to threads on attaching bolts (70, 71, 73).
Secure starter adapter, accessory drive adapter
and compressor mount bracket(63) to accessory
case with attaching parts (68 through 74). Torque
bolts to 155-175 inch pounds. Do not torque freon
compressor bracket and starter adapter to
accessory case nut (72) at this time.
Chapter 19
5. Freon compressor bracket alignment
NOTE…
nuts. Instructions for construction of this tool
are shown in Figure 19-15.
If the engine is equipped with the large air pump
required for aircraft de-ice equipment, it will be
necessary to remove the rear freon compressor
bracket prior to pump replacement. A complete freon
compressor bracket alignment will be necessary
upon replacement of this air pump.
e. Torque rear freon compressor bracket nuts to
90-110 inch pounds. Safety wire in
accordance with Section 4-2, "Lockwire
Procedure."
Alignment procedure:
a. Insure special spacer washers are behind
bracket as shown in Figure 19-14, Detail B &
C. Snug fasteners finger tight.
g. Install freon compressor in accordance with
the airframe manufacturer's instructions.
b. Insure remaining hardware is installed as
shown in Figure 19-14.
c. Install alignment fixture in freon compressor
location as shown in Figure 19-15. See Figure
19-15 for alignment fixture specifications.
Secure with 3/8 inch bolts, washers and nuts
two places. Torque front freon compressor
bracket nut (72) to 180-220 inch pounds.
d. When installing the air pump between the
compressor mount brackets, a special tool is
also required to torque the lower hold down
f.
Remove nuts, bolts and alignment fixture.
h. Install freon compressor drive belt in
accordance with the airframe manufacturer's
instructions.
i.
After minimum of twenty (20) minutes and a
maximum of two (2) hours run-in with
compressor loaded, re-tension the drive belt
in
accordance
with
the
airframe
manufacturer's instructions.
3. See Figure 6-5. Lubricate o-ring (28) with clean
50 wt. aviation engine oil and install on starter
pilot. Turn starter shaft until tongue aligns with
worm drive shaft slot. Mount starter (29) and
secure with attaching parts (30, 31). Torque nuts
(31) to 200-220 inch pounds.
19-16
Chapter 19
FIGURE 19-14. STARTER AND FREON COMPRESSOR BRACKETS
19-16
Chapter 19
FIGURE 19-15. COMPRESSOR BRACKET ALIGNMENT
19-17
Chapter 19
19-8 STARTER ADAPTER AND
STARTER MOTOR LTSI0-360-RB
(See Figure 6-9.)
1. Apply a thin coat of TCM Gasket Maker 646942
to the crankcase mating surface only.
3. Secure alternator with attaching hardware (2,3).
The alternator drive belt and sheave must be
installed in accordance with the airframe
manufacturer’s instructions. After drive belt and
sheave installation nuts (3) must be torqued to
180-220 inch pounds.
CAUTION…
Sealant must be applied sparingly to prevent
contamination of the engine oil system.
2. Lubricate starter shaftgear teeth with clean 50
weight aviation engine oil and mesh with
crankshaft gear teeth as adapter is placed in
position. Seat adapter against gasket. Secure
adapter assembly to crankcase with attaching
parts (39, 49 through 54). Torque bolts to
155-175 inch pounds. Torque nut (39) to 180-220
inch pounds.
3. Lubricate o-ring (45) with clean 50 wt. aviation
engine oil and install on starter pilot. Turn starter
shaft until tongue aligns with worm drive shaft
slot. Mount starter (46) and secure with attaching
parts (47, 48). Torque nuts (48) to 200-220 inch
pounds.
19-9 ALTERNATOR
ASSEMBLY (See Figure 6-6.)
1. Position alternator (1) on alternator mount bracket
(3). Align alternator support bolt hole with upper
mount bracket bolt hole and install washer (5) and
bolt (4). Install washer (5) and nut (7) on bolt (4).
2. Install bracket (8) on alternator mount bracket (3)
and secure using bolt (14), washers (12) and nut
(13). Align adjusting bracket (8) and torque nut,
bolt to 200-275 inch pounds.
19-18
19-10 VALVE MECHANISM
(See Figure 6-15.)
1. Lubricate all tappet faces using Dow Corning®
G-N Paste or equivalent. [Dow Corning® is a
registered trademark of Dow Corning
Corporation.]
2. Install exhaust tappets into exhaust side tappet
guides. Install intake tappets into intake side
tappet guides.
3. Install twelve pushrod housings. Install the
pushrod housings nearest to engine mount
brackets first. The spring compressor tool must lie
close to horizontal in order to clear the crankcase
flange. Using a Borrough's 68-3 Rod Spring
Compressor or equivalent, compress spring (38).
Place a new packing (40) between two steel
washers (39) and install on the crankcase end of
pushrod housing. Place a new gasket (37) on the
cylinder end of pushrod housing. Insert housing
into crankcase guide until other end can be
aligned with cylinder head opening. Move
assembly outward until gasket has entered
cylinder hole.
4. Release spring slowly until it is free. Remove
spring compressor. See Figure 19-18, "General
View Installing Pushrod Housing."
5. Lubricate pushrods (41) with clean 50 weight
aviation engine oil and install through cylinder
openings into housings (36).
Chapter 19
FIGURE 19-16. ROCKER ARM TO ROTOCOIL CLEARANCE
WARNING
Correct rocker shaft retaining nut torque can
only be achieved if lifters are completely bled
down, valves are closed and no load is applied
to rocker assembly.
6. Before installing valve actuating parts on each
cylinder, turn the crankshaft until pushrods are at
their lowest position. Lubricate rocker assemblies,
thrust washers and rocker shafts using clean 50
weight aviation engine oil. Install rocker
assemblies (19) and thrust washers (22) on rocker
shafts (23). Check parts catalog for proper
identification of exhaust and intake rocker arm.
Install rocker and shaft assemblies on cylinder in
correct positions. Install retainers (24), tab
washers (25) and nuts (26). Torque nuts (26) to
110 - 120 inch pounds.
7. Check side clearance between retainers and
rocker arms. See Figure 19-17, "Checking Rocker
Arm Side Clearance."
8. Rocker arm to rotocoil clearance must be checked
with the valve in the closed position and the foot
of the rocker in contact with the valve stem tip.
9. Measure rocker arm to rotocoil clearance. See
Figure 19-16, "Rocker Arm To Rotocoil
Clearance. See Section 16-5 for rework
procedure.
10. Measure dry valve gear lash at valve tip to rocker
foot and compare with limits given in Figure
16-3, "Cylinder Fits and Limits." Bend tab
washers (25) flat up against head of nuts (26) to
safety. See Section 4-3, "Tab Washer Procedure."
CAUTION…
Do not realign nut flats to suit tab washer.
11. Install pushrods (41) and valve actuating
mechanism (19 through 26) on remaining
cylinders using the same procedure in paragraphs
5 through 10.
12. Using new gaskets (27), install rocker covers (28)
and secure with attaching hardware (30, 31, 32,
33). Do not torque screws (32) or (33) at this
time. The rocker covers will be removed for
engine pre-oiling in Section 20-2.
19-19
1. Install baffle assemblies (12, 13) between
cylinders and secure with spacers (1) and bolts
(5). Do not torque bolts (5) at this time.
2. Install supports (2) between cylinders and secure
baffle assemblies (12,13) using new springs and
fasteners (8,9).
3. Insure all interconnecting baffle grooves are in
place and torque bolts (5 and 3) to 36-50 inch
pounds.
19-12 CYLINDER DRAIN
ASSEMBLIES (See Figure 6-15.)
FIGURE 19-17. CHECKING ROCKER
ARM SIDE CLEARANCE
19-11 CYLINDER BAFFLING
(See Figure 6-14.)
1. Position baffles (6, 7, 10, 11) and supports (4) on
cylinders. Secure baffles (6, 7, 10, 11) to supports
(4) with washers (14) and bolts (3). Do not torque
bolts (3) at this time.
1. Coat the male tapered threads of fittings (18) with
Loctite Pipe Sealant With Teflon P S/T. Coat the
male tapered threads only. Install fittings (18) in
cylinders. Torque to limit specified in Table 6-4,
"Hydraulic Line Fitting Torques."
2. Install cylinder drain tube assemblies (42) on
cylinders. Torque drain tube "B" nuts to the limit
specified in Table 6-4, "Hydraulic Line Fitting
Tightening Torques." Drain valve assemblies
must be installed in accordance with the airframe
manufacturer's instructions.
FIGURE 19-18. GENERAL VIEW INSTALLING PUSHROD HOUSING
19-20
Chapter 19
19-13 EXHAUST SYSTEM (See
Figure 6-1.)
36). Torque bolts (32) to 155-175 inch pounds
and torque bolts (36) to 220-260 inch pounds.
1. Slide riser assemblies (1, 3, and 5) together to
make up 2-4-6 side collector assembly. Slide riser
assemblies (2, 4, 6 and 7) together to make up
1-3-5 side collector assembly.
2. Install fittings (51, 52) into turbocharger oil inlet
adapter. Install check valve (54) on fitting (51).
Install fitting (56) into turbocharger oil outlet
adapter. Torque fittings in accordance with Table
6-4, "Hydraulic Line Fitting Torques."
2. With engine in inverted position install six
exhaust flange gaskets (18) . Holding R.H. 1-3-5
side collector assembly together, carefully install
on R.H. cylinder exhaust ports, position collector
so that flanges seat squarely on ports and secure
with nuts (19).
3. Install turbocharger and aftercooler support
brackets (45, 46) on crankcase mounted
turbocharger support bracket (47). Secure with
attaching hardware (48, 49, 50). Align brackets
(45, 46, 47) and torque bolts (48) and new nuts
(50) to 180-220 inch pounds.
3. Using same procedure above, install 2-4-6 side
collector assembly, torque all nuts (19) to
200-210 inch pounds.
4. Turbocharger (21) is attached to bracket (45) with
bolts (44) and tab washers (76). Align
turbocharger with bracket, install bolts (44) and
new tab washers (76). Torque bolts to 155-175
inch pounds. Bend tab washers (76) flat up
against head of bolts (44) to safety. See Section
4-3, "Tab Washer Procedure."
4. Install exhaust manifold (9) on exhaust elbows (7,
8) and secure with new clamps (12), tie rods (13,
17), bolts, washers (14) and new nuts (16).
Torque clamp and tie rod bolts and nuts in
accordance with Table 6-2, "General Use
Torques.
1. Using new gaskets (29, 33), install adapters (30,
34) on turbocharger as shown. Secure adapters
using new lock washers (31, 35) and bolts (32,
5. Secure turbocharger to exhaust manifold using a
new gasket (20), bracket (22), bolts (26), washers
(27) and new nuts (28). Torque nuts (28) and
bolts (26) to 90-110 inch pounds.
FIGURE 19-19. MULTI-SEGMENT “V” BAND CLAMP
19-21
Chapter 19
6. Using new gasket (37), install wastegate assembly
(38) on exhaust manifold (9) and secure with
bolts (39, 40), washers (41) and new nuts (42).
Using a new gasket (37), install tube (11) on
wastegate (38) and secure with bolts (39, 40),
washers (41) and new nuts (42). Torque bolts (39,
40) and new nuts (42) to 240-280 inch pounds.
7. Slide tailpipe assembly (10) onto tube (11) and
align with turbocharger exhaust outlet flange.
Install a new clamp (43) on tailpipe and
turbocharger flanges. Install new clamp insuring
“V” segments go over exhaust flanges, using a
rawhide or plastic mallet, tap clamp
circumferentially as clamp is torqued to 35-40
inch pounds.
1. Install aftercooler (26) on aftercooler mount
bracket (27) and secure using new lock washers
(29) and nuts ((30). Torque nuts (30) to 75-85
inch pounds.
2. Using a new gasket (1), new lock washers (4),
washers (3) and screws (5) assemble servo and
throttle adapter unit to intake manifold (2).
Torque screws (5) to 155-175 inch pounds.
3. Install fitting (35) in intake manifold (2).
4. Loosely assemble intake tubes and flanges (6
through 13) and (14) to intake manifold (2) using
new hoses and clamp assemblies (19, 20).
5. Place new gaskets (15) on cylinder intake flanges.
8. Install clamp (23) on tailpipe assembly and secure
to bracket (22) using bolt (24) and new nut (25).
Torque bolt (24) and nut (25) to 180-220 inch
pounds.
9. Using a new o-ring (66), install fitting (67) into
wastegate assembly. Using new o-rings (62),
install fittings (63) into wastegate assembly.
Torque fittings in accordance with Table 5-4,
"Torque Specifications for Fittings."
10. Install oil filter adapter to wastegate hose
assembly (64). Install wastegate to controller hose
assembly (68). Install turbocharger oil supply
hose assembly (53). Install turbocharger oil
supply hose clamp (71), brackets (72) or (73),
bolts (70), washers (74), and nuts (75). Install
turbocharger to scavenge pump hoses (59, 57).
Install new check valve (58). Torque all hose
assembly "B" nuts and fittings in accordance with
Table 5-4, " Torque Specifications for Fittings."
19-14 INDUCTION SYSTEM
(See Figure 6-4.)
19-22
6. Apply a small amount of TCM 646439 adhesive
to new bumper (33), place bumper (33) on
underside of intake manifold (2) where it will
mate with the crankcase backbone.
7. With the aid of an assistant, place intake spider
assembly on top of engine. Adjust intake tubes so
they seat squarely on cylinder flanges and secure
with attaching hardware (16, 17, 18). Torque nuts
(18) to 50-70 inch pounds. Torque all clamps (19)
to 40-50 inch pounds.
8. Using new hoses (21, 24) , install elbow (22)
between throttle adapter assembly and aftercooler
(26).
9. Install a new hose (32) and clamp assembly (23)
between aftercooler and turbocharger compressor
housing.
10. Torque hose clamps (23, 25) to 40-50 inch
pounds.
Chapter 19
19-15 FUEL INJECTION
SYSTEM (See Figure 6-3.)
1. Apply Molyshield grease to splines on fuel pump
drive shaft (63). Install fuel pump drive shaft in
engine meshing splines with governor drive gear
internal splines. Install new gasket (62) on fuel
pump. Lubricate fuel pump cavity with clean 50
weight aviation engine oil. Install fuel pump on
crankcase studs. Secure fuel pump using washers
(59), new lock washers (60) and nuts (61). Torque
nuts (61) to 180-220 inch pounds.
2. Install fuel hoses (42, 44) and fitting (43) between
fuel servo unit and fuel pump. Install air reference
hose (37) between fuel pump and air throttle
adapter. Install fuel hose (46) between fuel servo
unit and fuel manifold valve. Torque hose "B"
nuts to the specified limit in Table 5-5, " Torque
Specifications for Hose Fittings."
6. Install 2-4-6 side air reference manifold and tube
(41, 39) on sleeves (70) and throttle adapter
connection. Install air reference manifold and tube
(40, 41) on the 1-3-5 side sleeves and attach to
throttle connection. Install the air reference sleeve
nuts on the air reference manifold male
connectors and turn with fingers until each seal is
seated between nut and male connector. Using an
open end wrench, tighten the air reference sleeve
nuts an additional 3/4 to 1 turn. Avoid deforming
the rubber seals. With air reference tubes installed
and sleeves properly positioned, install new
rubber washer (56) next to nozzle, install new
steel washer over rubber washer on each fuel
nozzle. Install fuel injection lines (49 through 54)
between nozzles and fuel manifold valve. Torque
fuel injection line "B" nuts (49 through 54) at
nozzles to 40-45 inch pounds. Torque fuel line
"B" nuts at manifold valve to 55-60 inch pounds.
CAUTION…
3. Install hoses (72, 73) between controller (2) and
turbocharger wastegate. Torque hose "B" nuts to
the specified limit in Table 5-5, " Torque
Specifications for Hose Fittings."
4. Install new o-rings (57) on fuel nozzles (58),
apply 646943 anti seize lubricant to nozzle
threads (cylinder end) and install fuel nozzles (58)
in cylinders 1 through 6. Torque nozzles to 55-65
inch pounds.
5. Carefully slide sleeves (70) onto nozzles do not
damage o-rings (55).
Never use teflon tape on fuel injection system fittings.
WARNING
Fuel injection lines must not be
deformed. The fuel injection lines
securely clamped to the fuel line
brackets. Do not assemble in a
condition.
bent or
must be
support
binding
7. Attach clamps (65, 66) to fuel lines (49 through
54) and induction tubes. Torque nuts and bolts
(68, 69) to 36-50 inch pounds.
19-23
Chapter 19
19-16 ENGINE TIMING
POSITION PROCEDURE (See
Figures 19-20 through 19-24.)
NOTE…
The engine is equipped with a right angle drive starter
adapter. If it does not freely turn in the opposite
direction of normal rotation the starter motor must be
removed from the starter adapter. Some right angle
starter drive adapters incorporate an over-riding
spring clutch design that restricts engine rotation in
the opposite direction of normal rotation.
NOTE…
Whenever positioning the crankshaft for magneto
installation, always turn the crankshaft steadily in
the direction of rotation to eliminate any backlash
error.
In conducting magneto timing check, use a top dead
center locator, protractor and pointer such as the
Eastern Electronics Model E25 Timing Indicator or
equivalent.
Use the following basic timing procedure to insure
that timing is accomplished in accordance with the
required specifications.
Ignition Timing (Compression stroke, breaker opens)
Right Magneto, degrees BTC
22° ± 1°
Left Magneto, degrees BTC
22° ± 1°
1. Remove all top spark plugs. Rotate the
crankshaft in the direction of normal rotation
until the number one piston is at top dead center
on the compression stroke. Rotate the crankshaft
in the opposite direction of normal rotation until
the piston is far enough down the barrel to allow
the TDC locator to be installed.
2. Install the top dead center locator into No. 1
cylinder top spark plug hole.
3. Install timing disc of indicator being used on the
crankshaft flange.
4. Turn crankshaft slowly in direction of normal
rotation until piston lightly touches TDC locator.
5. Rotate disc of timing indicator until the 0 degree
mark aligns with the pointer.
FIGURE 19-20. TIMING POSITION STEP ONE
19-24
Chapter 19
6. Slowly turn crankshaft in opposite direction of normal rotation until the piston lightly touches TDC
locator.
FIGURE 19-21. TIMING POSITION STEP TWO
7. Observe reading on the disc under the pointer and move the disc, to exactly one-half of the number of
degrees observed, toward the top center mark.
FIGURE 19-22. TIMING POSITION STEP THREE
19-25
Chapter 19
8. This will be approximately one-half the number of degrees remaining of 360 degrees of crankshaft
rotation. You have now located top dead center.
FIGURE 19-23. TIMING POSITION STEP FOUR
9. Remove the TDC locator from the cylinder and find the compression stroke on No. 1 cylinder by placing a
finger over the spark plug hole, or any other adequate method. As you come up on compression, stop the
pointer at the TDC location as determined in step 8.
FIGURE 19-24. TIMING POSITION STEP FIVE
19-26
Chapter 19
10. To to place the crankshaft in the correct timing
position for magneto installation, move the
crankshaft in the opposite direction of normal
rotation past the specified magneto timing
setting and then back in the direction of normal
rotation until the desired setting before top dead
center is under the pointer. (This removes gear
backlash).
19-17 MAGNETO TIMING AND
INSTALLATION ON ENGINE
WARNING
Prior to any engine or magneto timing
procedure disconnect all ignition harness
spark plug leads from the spark plugs. Do not
attach any ignition harness spark plug leads to
the spark plugs until all magneto, engine
timing procedures and magneto to switch
connections have been entirely completed. The
magneto is in a SWITCH ON condition when
the switch wire is disconnected. To prevent
possibility of serious bodily injury or death,
before moving the propeller accomplish the
following:
a. Disconnect all spark plug leads.
b. Verify magneto switches are connected
to magnetos, that they are in the"OFF"
Position and "P" leads are grounded.
c. Throttle position "CLOSED."
d. Mixture control "IDLE-CUT-OFF."
e. Set brakes and block aircraft wheels.
f. Insure that aircraft tie-downs are
installed and verify that the cabin door
latch is open.
g. Do not stand within the arc of the
propeller blades while turning the
propeller.
1. Insert the T118 timing pin in "L" or "R" hole
(depending on magneto rotation) in the distributor
block. Turn rotor in the opposite rotation of
magneto until pin engages the gear.
2. See Figure 6-2. Clean and dry the retainers (7)
and bushings (6). Apply Molyshield grease to the
rubber drive bushings and the magneto drive gear
needle bearings. Install two magneto drive
bushings into each retainer with the radius
(rounded) edges facing outward. Install a retainer
and bushing assembly firmly into each magneto
drive gear assembly. Install both of the magneto
drive gear assemblies on their support shafts.
WARNING
Any debris that falls into the engine interior
must be removed prior to engine operation.
WARNING
Incorrect magneto to engine timing will cause
detonation, engine failure, injury or death.
3. Insure that the crankshaft is positioned in
accordance with Section 19-16 "Engine Timing
Position Procedure."
4. Without turning the magneto coupling, hold the
magneto in the position it will occupy when
installed. Check the alignment of the gear
coupling slot and impulse coupling lugs. If not
aligned, pull the magneto drive gear out of mesh
and turn to position needed. Push gear back into
mesh.
5. Place a new gasket on the magneto flange and
install magneto carefully so that the drive
coupling lugs mate with the slots of the drive
bushings.
6. Install holding clamps, lock washers and nuts.
Snug nuts but do not torque. This will allow
turning of the magnetos for final timing. Remove
the T118 timing pins from Slick magnetos.
7. Using the above procedure, paragraphs 1 through
4, install the remaining magneto.
8. The magneto timing light breaker point leads are
connected to the ground terminals of the
magnetos. The timing light breaker point leads are
connected so that the light on the right side of the
timing light box represents the right magneto and
the light on the left side of the timing light box
Chapter
19
represents
the the left magneto. The timing
lights should indicate that the points in both
magnetos are closed. Tap the right magneto up
with a non-marring hammer until the light
indicates points just opening. Tap the left
19-27
magneto down until the light indicates points just
opening. Secure magnetos.
10. Torque the magneto attaching hardware to 100 120 inch pounds.
9. Watch the lights on the magneto timing light.
Turn
the
crankshaft
a
few
degrees
counterclockwise then clockwise until the timing
indicator's pointer is pointing to the correct
degree. As the pointer aligns with the correct
degree both lights on the magneto timing light
must indicate that the points just open within
one-half-degree of crankshaft rotation. If timing
light does not indicate the above re-adjust the
magnetos.
11. Disconnect timing light from magnetos. Insure
that connections between magneto and ignition
switch are secure.
NOTE…
Point opening is indicated by light illumination on
some timing lights while other timing lights operate in
the reverse manner, i.e., the light goes out when the
points open.
CAUTION…
When installing the magneto on the engine using the
specified nuts and clamps, take the following
precautions. Tighten both nuts by hand to finger
tightness. Torque each nut alternately to 100 to 120
inch pounds. Exceeding 120 inch pounds torque may
cause the mounting flange to crack.
19-18 IGNITION HARNESS
PRE- INSTALLATION
INSTRUCTIONS
1. The ignition harness assembly must be replaced
100% at engine overhaul.
2. Clean the mating surfaces (grommets and
inside of the outlet plate) with a lint free cloth
moistened with isopropyl alcohol. Apply
MS122N/C02 Spray before installing harness
on
magneto.
MS122N/C02
Spray,
Miller-Stephenson Chemical Co., Inc., 16
Sugar Hollow Road, Danbury, Connecticut
06810. Carefully place the harness outlet plate
onto the magneto insuring the grommets enter
the distributor block towers. Install and torque
nuts around plate alternately to seat cover
squarely on magneto. Torque screws in
accordance with the magneto manufacturer's
instructions.
FIGURE 19-25. COATING INSULATING SLEEVE
19-28
Chapter 19
1. The harness assemblies are constructed of a
lightweight, flexible, silicone coated cable.
Because the harness assemblies are lightweight
and flexible the following must be observed when
installing the harness on an engine:
a. Support leads with the necessary clamps and
cable ties to prevent any whipping or chafing
action.
b. Route leads as far away as possible from
exhaust manifold to insure they are not
exposed to temperatures in excess of 400°F.
c. To prevent sticking of sleeves and to
minimize twisting of ferrule coat insulating
sleeves,
use
MS122N/C02
Spray,
Miller-Stephenson Chemical Co., Inc., 16
Sugar Hollow Road, Danbury, Connecticut
06810. See Figure 19-25, "Coating Insulating
Sleeve."
NOTE…
Hold ferrules while torquing or loosening spark plug
coupling nuts to protect against twisting conduit or
cable.
d. Clamp harness leads as required.
19-19 IGNITION HARNESS
INSTALLATION
2. Apply Champion® thread lubricant to spark plug
threads in accordance with the manufacturer's
instructions. Install all spark plugs and torque to
300-360 inch pounds.
3. Secure the ignition leads to the cylinder rocker
covers using the ignition lead clamps and rocker
cover screws. Use caution routing and attaching
leads. Keep leads away from high heat sources
such as the exhaust manifold. Keep the leads
away from any engine component that may cause
chafing.
4. Connect the right magneto switch ground wire to
the right magneto and the left magneto switch
ground wire to the left magneto in accordance
with the magneto manufacturer's instructions.
5. Install the ignition leads on the proper spark plugs
and screw on. Torque ignition lead coupling nuts
to 110 - 120 inch pounds.
Spark Plug
Coupling Thread
5/8 - 24
3/4 - 20
Torque
(inch pounds)
90 - 95
110 - 120
TABLE 19-1 COUPLING NUT TORQUE
VALUES
6. The mechanic must consult all related service
information issued by the ignition harness
manufacturer.
(continued)
1. The cable outlet plates can be attached to either
magneto in only one position. The shortest
ignition cable is for No. 1 upper spark plug. The
ignition lead to spark plug positions are stamped
on the ignition lead to spark plug nuts.
19-29
Chapter 19
PRESSURIZATION PLUMBING
INSTALLATION
1. See Figure 6-2. Coat fitting (19) tapered end
threads with Loctite #242. Install bushings (20)
and fittings (19) in magnetos. Torque bushings
and fittings in accordance with Table 5-4,
“Hydraulic Line Fitting Torques.
Install new hoses (12, 15, 16, 17), clamp
assemblies (18), new filter (14), reducer (29),
and tee (13) on magnetos as shown in Figure 62. Filter drain (reducer) must be to rear of
engine. Connect loose end of hose (9) to air
manifold adapter hose fitting and secure with
clamp (18). Torque hose clamps (18) to 10-14
inch pounds. Do not over torque clamps to the
point of cold flow.
FIGURE 19-26. IGNITION WIRING DIAGRAM
19-30
Chapter 20
CHAPTER 20
POST OVERHAUL ADJUSTMENT AND TEST
SECTION
20-1
20-2
20-3
20-4
20-5
20-6
20-7
20-8
20-9
20-10
20-11
20-12
20-13
20-14
20-15
20-16
20-17
20-18
20-19
20-20
20-21
PAGE
Testing After Overhaul........................................................................... 20-3
Engine Pre-Oiling ................................................................................... 20-3
Test Stand................................................................................................ 20-3
Test Club................................................................................................. 20-3
Cooling Air Scoop .................................................................................. 20-3
Induction Air Intake................................................................................ 20-3
Exhaust And Turbocharger System ....................................................... 20-4
Controls................................................................................................... 20-4
Electrical Wiring..................................................................................... 20-4
Instruments.............................................................................................. 20-4
Breather................................................................................................... 20-4
Fuel System............................................................................................. 20-4
Governor Pad Cover ............................................................................... 20-4
Engine Test ............................................................................................. 20-4
Oil Pressure Adjustment ........................................................................ 20-5
Fuel System Adjustment......................................................................... 20-6
Overhaul Test Run Standard Acceptance Test ...................................... 20-16
Oil Consumption Determination ............................................................ 20-17
Engine Preservation for Storage or Installation after overhaul.............. 20-18
Test Flight ............................................................................................... 20-18
Continued Airworthiness Instructions.................................................... 20-18
FIGURE
20-1
20-2
20-3
20-4
20-5
20-6
20-7
20-8
PAGE
Oil Pressure Relief Valve ....................................................................... 20-5
Fuel Pump Adjustment ........................................................................... 20-7
Fuel Servo Adjustments.......................................................................... 20-8
Controller Adjustment ............................................................................ 20-9
Admp Vs. Oil Temperature .................................................................... 20-10
Constant Speed Sea Level Performance Curve...................................... 20-13
Fuel Flow Vs. Metered Fuel Pressure .................................................... 20-14
Fuel Flow Vs. Brake Horsepower .......................................................... 20-15
TABLE
20-1
PAGE
Test Specifications.................................................................................. 20-11
Operational Test Form............................................................................ 20-12
20-1
Chapter 20
INTENTIONALLY
LEFT
BLANK
20-2
Chapter 20
20-1 TESTING AFTER
OVERHAUL
WARNING
During engine test run do not stand or allow
anyone else to stand in the propeller arc area.
20-2
ENGINE PRE-OILING
All engine internal moving parts must be properly
lubricated before initial running of the engine after
overhaul. Pre-oil the engine in accordance with the
following procedure:
1. Pre-oiling may be accomplished using a bladder
type pressure pot capable of holding at least 1
gallon of clean aviation engine oil with an output
pressure of 50 not to exceed 60 pounds per square
inch. See Section 2-4 for proper oil grade and for
approved oil products.
2. Remove rocker box covers from cylinders.
Connect pre-oiler supply hose to engine oil
pressure gauge line connection (fitting). Open
valve on pressure pot and watch cylinder rocker
areas for indication of oil flow. Some engines
may take as long as 20 minutes for oil indication
depending on oil temperature.
3. After oil flow has been confirmed, install rocker
box covers and gaskets. Torque rocker cover
screws to 55-65 inch pounds. Close valve on
pressure pot. Disconnect pressure pot supply hose
and cap or re-install engine oil pressure gauge on
pressure gauge line connection (fitting) as
applicable.
4. Check engine oil quantity and service to correct
capacity. See Chapter 7 of the L/TSIO-360-RB
Maintenance Manual, Form X30645A, for proper
oil grade and for approved oil products. Engine is
now ready for initial run-up and test.
20-3 TEST STAND
Engine performance must be tested after overhaul.
The engine stand must be constructed in a way to
permit accessibility to all engine line and instrument
cables used to connect instruments and controls must
be properly supported, and of sufficient flexibility to
permit them to be moved out of the way during
installation and removal of the engine.
NOTE…
When necessary, the airframe can be considered a
suitable test stand for running in overhauled engines
with the use of a test propeller and equipped with a
suitable shroud or scoop to gather and direct cooling
air over the cylinders. Engine must be equipped with
all the calibrated instruments listed in "Instruments" of
this section.
20-4
TEST CLUB
It will be necessary to install a test club such as those
supplied by the Hartzell Propeller Fan Co., Piqua,
Ohio or the flight propeller if the engine is installed in
the aircraft. Test clubs are customarily supplied in
standard diameters, so that the blade length is reduced
by the "cut and try" method. The club will absorb the
BHP at the RPM specified in Table 20-1. Use the test
club in combination with the cell, test stand and
operating limits for which it was calibrated.
20-5
COOLING AIR SCOOP
The scoop must be designed to fit over the tops of all
cylinders, with padded seals for rear cylinders and
valve rocker covers, to direct an adequate flow of air
downward through the cylinder fins. Vanes are
necessary to direct cooling air to the center cylinder
and the oil cooler. CHT should not vary more than
50°F. between coolest and hottest cylinders. Provide
an air duct to the alternator vent tube.
20-6
INDUCTION AIR INTAKE
An air filter and housing must be attached to the
turbocharger inlet flange. The filter area must be
sufficient to avoid restriction of air flow. Always
clean filter before each test, calculations of filter area
should be based on approximately 389 c.f.m. of air
required by the engine at full throttle and on the filter
capacity per unit of area. The calculated area of a
clean filter should be increased by at least 50% to
allow for dirt accumulation.
connections and to allow frequent inspection of all
points of possible leakage. All tubes, wires, rods and
20-3
Chapter 20
20-7 EXHAUST AND
TURBOCHARGER SYSTEM
For testing purposes, the exhaust and turbocharger
system supplied by Teledyne Continental Motors
must be installed.
20-8
CONTROLS
The only controls required are a mixture control and
throttle control capable of operating the fuel control
and throttle shafts through their complete ranges, and
a magneto switch connected to the magneto ground
terminals. If a flight propeller is used, a proper
governor control is also required.
20-9
ELECTRICAL WIRING
A storage battery must be connected by a No. 0
stranded copper cable from its positive terminal to the
power terminal of the starter or starter solenoid. The
battery negative terminal must be connected to the
engine or both battery terminal and engine may be
grounded. A small insulated wire should connect the
starter solenoid coil terminal to a 5 ampere
push-button switch. The other switch terminal must be
connected to the engine or both to common ground.
20-10 INSTRUMENTS
The control panel must be equipped with the
following calibrated engine instruments.
1. An electrical tachometer compatible with the
electrical magneto pick-up.
20-11 BREATHER
A clean, substantial hose of 3/4 inch ID must be
installed on the crankcase breather elbow and support
so it leads to a point above and to the rear of engine.
20-12
FUEL SYSTEM
The test stand fuel system is to incorporate an
auxiliary pump capable of delivering fuel to and
through engine system at a pressure of 2 to 2-1/2 psi
indication on fuel pressure gauge. Connect fuel supply
line to upper elbow projecting from left side of fuel
pump. Connect fuel pump-to-supply tank return line
to upper elbow projecting from right side of fuel
pump. Connect fuel pressure gauge line to the fitting
projecting from the center rear of fuel manifold valve.
20-13 GOVERNOR PAD
COVER
A removable oil transfer plug directs oil under
pressure from the front main bearing through the
crankshaft to the propeller hub. The crankshaft and
front main bearing design provide passages for
governor controlled oil to the crankshaft for use with
an oil controlled propeller. When a test club or fixed
pitch propeller is used for testing purposes, the
governor pad cover must have an internal grooved
surface to allow the circulating oil to flow to the
crankshaft oil control plug. The governor pad cover is
not needed if a propeller governor is installed.
20-14
ENGINE TEST
2. An oil pressure gauge and tube connection.
WARNING
3. An oil temperature gauge and capillary assembly.
4. A cylinder head temperature gauge and wiring to
each cylinder. See test operating limitations for
different maximum temperatures.
Over priming can cause hydrostatic lock and
subsequent engine failure.
5. A water manometer with rubber hose connection
to the vacuum pump oil return hole at the rear of
the crankcase.
CAUTION…
6. An ammeter connected in the generator or
alternator circuit.
7. Fuel flow gauge or fuel pressure gauge.
8. A turbine inlet temperature gauge.
9. Manifold pressure gauge.
20-4
Insure propeller area is clear before initiating
starting sequence.
Chapter 20
NOTE…
Before starting engine, perform step one of “PreSetup Procedure” in Section 20-16. Insure that fuel
tanks contain proper type of fuel (100LL-blue or 100
green). Check engine oil sump for proper servicing.
See section 2-4 for oil type and specification.
Start the engine in accordance with the airframe
manufacturer's Airplane Flight Manual (AFM.)
Operate the engine at 750 RPM for one minute,
gradually increasing RPM to 1000 RPM in three
minutes.
Check the magneto circuit for proper grounding prior
to a normal shut-down. Allow the engine to cool
adequately and make a visual inspection for any
discrepancies. If engine exhibits any discrepancies,
return to the applicable chapter to correct the
discrepancy. All discrepancies must be corrected prior
to engine adjustment.
Oil Pressure - Check, If oil pressure is not indicated
within 30 seconds, shut engine down and investigate.
CAUTION…
Operation of engine without oil pressure may result in
engine malfunction or failure.
When propeller stops rotating, place ignition switch,
master switch and fuel selector in off position.
20-15 OIL PRESSURE
ADJUSTMENT
The adjusting screw is turned clockwise to increase
oil pressure and counterclockwise to decrease oil
pressure. With normal operating oil temperature (160°
- 200°F), adjust oil pressure to maintain, 30-80
pounds per square inch at full power RPM. Torque
locknut and safety as required.
FIGURE 20-1. OIL PRESSURE ADJUSTMENT
20-5
Chapter 20
20-16 FUEL SYTEM
ADJUSTMENT AND SETUP
be inaccurate must be repaired or replaced prior
to adjusting the fuel system.
WARNING
WARNING
The procedures and values provided apply to
TCM fuel injected engines that have not been
modified from their type design. Refer to
supplemental type certificate (STC) holder
information and instructions for aircraft and
engines that have been modified from their
type design.
Use of inaccurate gauges will result in
incorrect adjustment of the engine fuel
system, which may result in excessive
cylinder wear due to lean operation, preignition, detonation, loss of power and severe
engine damage.
CAUTION...
Engine performance, service life and reliability will
be compromised if the engine's fuel injection system
is neglected.
The following adjustment procedures are presented
in a sequential format that must be followed to
insure proper fuel system adjustment. Reference the
applicable Aircraft Maintenance Manual for detailed
fuel system adjustment and maintenance procedures.
Any fuel system that can not be adjusted to meet the
specified values will require repair or replacement of
the affected components prior to further engine
operation.
3. Insure that all fuel system components are of the
correct part number and installed properly.
Correct any discrepancies noted.
4. Remove, inspect, clean and reinstall the engine
test stand or aircraft and engine fuel screens in
accordance with the manufacturer's instructions.
5. If the engine is installed in the airframe for
testing, inspect the aircraft induction air filter
and alternate air system for condition, operation
and cleanliness.
Repair or replace any
component that is not operating properly in
accordance with the manufacturer's instructions.
CAUTION...
Refer to Chapter 5, Tables 5-4 and 5-5 for specified
values when torquing all hose connections and
fittings.
6. Inspect the test stand or aircraft vapor return
system for proper operation in accordance with
the manufacturers instructions. Correct any
discrepancies noted.
PRE-SETUP PROCEDURES
7. Insure the fuel manifold valve vent and fuel
pump drain lines are properly installed, open and
free of obstruction. Correct any discrepancies
noted.
1. Insure that the test stand fuel supply is not
contaminated. If the engine is installed in the
airframe for testing, flush the aircraft fuel
system by first removing the engine driven fuel
pump inlet hose and terminating the end into a
large clean container. Operate the aircraft boost
pump and allow a minimum of one gallon fuel to
flow through the system. Take necessary
precautions to prevent a fire hazard. If
contamination is present, locate and correct the
source, and repeat this step prior to proceeding.
2. Prior to any checks or adjustments, verify the
accuracy of the tachometer, manifold pressure
gauge and fuel flow gauge. Any gauge found to
20-6
8. Inspect all engine control rod ends for wear,
freedom of movement, proper installation and
security in accordance with the test stand or
aircraft manufacturer's instructions. Correct any
discrepancies noted.
Chapter 20
9. Insure all engine controls operate freely
throughout their full range of travel and are
properly adjusted in accordance with the test
stand or aircraft manufacturer's instructions.
10. Lubricate all control rod ends and fuel system
components in accordance with the latest
revision of the L/TSIO-360 Maintenance
Manual, Form X30645A and the Test stand or
aircraft manufacturer’s instructions.
WARNING
Failure to correctly install and maintain
engine controls can result in loss of system
control and subsequent engine power.
Fuel System Adjustment
Verify that the engine test stand or aircraft fuel system
is operating properly in accordance with the
manufacturer's instructions before performing any
engine fuel system setup procedures.
NOTE:...
A currently calibrated Porta-Test Unit Model number
20 ATM-C manufactured by Aero Test, Inc.© or
equivalent must be used to adjust the fuel system. The
Porta-Test Unit must be connected and operated in
accordance with the manufacturer's instructions.
Use the operational test form on page 20-12 to
record the specifications in Table 20-1 and the actual
gauge indications. Start the engine in accordance with
Section 20-14. Advance the throttle to 1500 to 1800
RPM. While monitoring all engine gauges, operate
the engine at this speed until the engine temperatures
and pressures have stabilized in the operational
range.
Adjust the engine fuel system as follows:
Engine-driven fuel pump:
With the engine operating at 2600 rpm and 38.0
inches Hg. manifold pressure mixtures to 24.0 to 25.0
gallons per hour, and the emergency fuel pumps in the
off position, verify the the engine-driven fuel pump
discharge pressure is set to 35-45 psig. If the engine
driven fuel pump pressure does not fall within this
range, the fuel pressure may be adjusted by the
following method:
1. Loosen jam nut on fuel pressure adjustment.
2. Adjust screw clockwise to increase fuel pressure,
or counter-clockwise to decrease pressure.
FIGURE 20-2. FUEL PUMP ADJUSTMENT
20-7
Chapter 20
1. Repeat static run-up and readjust pressure as
required to obtain fuel pump pressure of 35 to 45
psig.
3. Slowly but positively, move the mixture control
from full rich to idle cutoff. The engine speed
should increase 25 to 50 rpm before beginning to
drop toward zero.
2. Torque the fuel pump jam nut to 30 inch pounds.
3. Idle Mixture: Check and adjust idle mixture as
follows:
Idle Performance
1. Operate the engine at 1500 to 1800 rpm until
cylinder head temperatures are 250°F to 350°F
and the oil temperature is 160°F to 180°F.
2. Reduce the engine speed and stabilize it at 700±
25 rpm.
4. If the engine speed increase is less that 25 rpm,
adjust the idle mixture link rod to enrich the
mixture. If the engine speed increase is more that
50 rpm, adjust the idle mixture link rod to lean the
mixture. The idle mixture adjustment is made by
lengthening (richening) or shortening (leaning)
the link rod between the throttle lever and the idle
valve lever. Recheck as required to insure the idle
mixture is adjusted within the limits specified
above. Each time an adjustment is made, clear the
engine by running it up to approximately 2000
rpm before making another mixture check.
FIGURE 20-3. FUEL SERVO ADJUSTMENTS
20-8
Chapter 20
Idle Speed: Check and adjust idle speed as follows:
1. Operate the engine at 1500 to 1800 rpm until
cylinder head temperatures are 250°F to 350°F
and the oil temperature is 160°F to 180°F.
2. Reduce engine speed and stabilize it at 700 ±25
rpm.
3. Adjust the idle speed screw that is located on the
aft side of the throttle lever until contact is made
with the throttle arm stop.
Full Power Performance: Check and adjust full
power performance as follows:
1. If the engine test is being performed in the
airframe orient the aircraft so that it is pointed
into the prevailing wind. Run the engine at 1500
to 1800 rpm until the oil temperature is 160°F to
180°F.
2. Using a handheld digital tachometer, adjust the
propeller controls to 2600 rpm. With the throttle
in the full forward position, set the intake
manifold pressure to the value shown in Figure
20-5 (± 0.5 In. Hg.) by adjusting the screw on the
top of the controller.
Turning the screw clockwise decreases manifold
pressure, and turning the screw counterclockwise
increases manifold pressure. One complete (360°) turn
of the screw changes the manifold pressure
approximately 1.0 inch.
FIGURE 20-4. CONTROLLER ADJUSTMENT
20-9
Chapter 20
FIGURE 20-5. ADMP VS. OIL TEMPERATURE
3. Adjust fuel flow rates: Set the engine to 2600
rpm, the manifold pressure to 38.0 Hg. and the
mixture controls to full rich. Adjust fuel flow
rates to the range of 24.0 to 25.0 gallons per hour
with the fuel flow adjustment knob that is located
on the top, left, side of the RSA-5 fuel servo.
Turn the knob clockwise to decrease the fuel flow
or counter-clockwise to increase. Turning the
knob seven clicks in either direction reduces or
increases fuel flow approximately 1 gallon per
hour. The final fuel flow setting shall not exceed
15 clicks in the counter-clockwise direction when
the knob is adjusted all the way in (lean).
Recheck
1. Recheck idle settings 700±25 RPM and adjust as
required.
2. Recheck full power settings as specified above
and adjust as required.
3. Remove test equipment in accordance with the
manufacturer's instructions.
4. After all ground checks and adjustments are
completed, safety wire mixture adjustment knob.
Torque "jam nuts" on the controller adjustment
screw and engine driven fuel pump to the limit
specified in Table 4-2, "General Use Torques," to
prevent the screw setting from changing.
20-10
CAUTION…
The engine should be run at idle RPM approximately
4 minutes before shutdown to allow the turbochargers
to spool down and thus prevent starvation of needed
lubricating oil.
POST SETUP PROCEDURES
1. Insure that the master switch, ignition switch
and fuel selector are in the off position.
2. Remove the engine cowling or cooling shroud in
accordance with the test stand or aircraft
manufacturer's instructions. Remove all test
gauges, fittings and hoses that were installed for
fuel system setup. Reconnect all fuel hoses to
their original locations, support and torque all
fittings to the specified value.
3. Perform a complete fuel system leak check.
Correct any discrepancies noted.
4. Install engine cowling or cooling shroud in
accordance with the test stand or aircraft
manufacturer's instructions.
Chapter 20
5. Perform a complete operational ground run-up
and verify that all fuel system performance
specifications are achieved.
Repeat the setup and adjustments as required until
the fuel injection system is performing within the
published specification for the aircraft and engine.
TABLE 20-1. TEST SPECIFICATIONS
For your convenience we have tabulated the following specifications to facilitate proper adjustment and optimum
performance.
ITEM
Full Throttle Speed - RPM
Idle Speed - RPM
Fuel Grade (Octane)
Fuel Flow at Full Throttle (Lbs. /Hr.)
Mixture Rise at Idle Cutoff - RPM
Oil Temperature Limit
Oil Pressure (Max. Oil Cold)
Minimum Oil Pressure at Idle
Oil Sump Capacity (Quarts)
Magneto Drop
(Max.) Magneto Spread
Cylinder Head Temperature with
Bayonet Thermocouple (Max.)
ENGINE MODEL L/TSIO-360-RB
2600
700±25
100LL/100
140-150
25 - 50
240°F
100
10
8
150 RPM
50 RPM
460°F
Proceed to standard acceptance and oil consumption determination as required for engine overhaul.
NOTE…
Test flight and documentation of all test flight operating parameters is MANDATORY before engine can be
returned to service. See section 20-17, "Test Flight."
See next page for Operational Test Form.
20-11
Chapter 20
20-12
Chapter 20
FIGURE 20-6. CONSTANT SPEED SEA LEVEL PERFORMANCE CURVE
20-13
Chapter 20
FIGURE 20-7. FUEL FLOW VS. METERED FUEL PRESSURE
20-14
Chapter 20
FIGURE 20-8. FUEL FLOW VS. BRAKE HORSEPOWER
20-15
Chapter 20
20-17
OVERHAUL TEST RUN STANDARD ACCEPTANCE TEST
PERIOD
1.
2.
3.
4.
5.
6.
7.
8.
TIME-MINUTES
5
5
5
10
RPM
1200±25 RPM
1600±25 RPM
 2450±25 RPM
Rated Power RPM
See Note 
10
75% Power RPM Check Fuel and
Oil Pressures. Check Temperatures.
5
Idle RPM (cooling period
300° Max. CHT at shut down.)‘
’ Stop engine and perform leak check.
15
75% Power RPM
15
5% Power RPM
NOTES:
 Make one check on performance of each magneto alone at 2100 RPM. Clear spark plugs by operating
with both magnetos on for a few seconds between checks.
 Do not run engine above 1800 RPM until oil temperature has reached 160°F and cylinder head
temperatures have reached 200°F.
‘ Do not shut engine down until oil temperature is below 200°F. and cylinder temperatures are below
300°F allow turbochargers time to spool down before shut down (except for emergencies).
’ Fuel and oil leaks are not acceptable.
Engines failing to pass acceptance test for high oil consumption, major oil leaks, low power damaged
components, excessive noise, excessive roughness, low oil pressure, excessive oil filter contamination require
further investigation, correction of all discrepancies and complete re-test.
See next page for oil consumption determination test run.
20-16
Chapter 20
20-18
OIL CONSUMPTION DETERMINATION
PERIOD
1.
2.
3.
4.
TIME-MINUTES
5
5
5
10
RPM
1200±25 RPM
1600±25 RPM
2450±25 RPM
Rated Power RPM
See Note 
5.
10
75% Power RPM Check Fuel and
Oil Pressures. Check Temperatures.
6.
5
75% Power RPM Check Fuel and
Oil Pressures. Check Temperatures.
Stop engine, drain and weigh oil in for oil consumption determination.
7.
5
Warm up to rated RPM
8.
30
Rated Power Take engine readings
every 10 minutes
9.
5
Idle RPM (cooling period
300° Max. CHT at shut down.)
NOTES:
 Make one check on performance of each magneto alone at 2100 RPM. Clear spark plugs by operating
with both magnetos on for a few seconds between checks.
 Do not run engine above 1800 RPM until oil temperature has reached 160°F and cylinder head
temperatures have reached 200°F.
‘ Do not shut engine down until oil temperature is below 200°F. and cylinder temperatures are below
300°F allow turbochargers time to spool down before shut down (except for emergencies).
Oil consumption of 1 lb. is considered acceptable for this test. One repeat of this
test run is acceptable. Oil consumption in excess of 1.0 pound return engine to
overhaul shop for a complete recheck of construction.
The oil consumption test run is a complete and separate test than the standard acceptance test.
20-17
Chapter 20
20-19 ENGINE PRESERVATION
FOR STORAGE OR
INSTALLATION AFTER
OVERHAUL
The engine must be preserved for storage or installed
in the airframe in accordance with the L/TSI0-360-RB
Maintenance Manual, Form X30645A and the
airframe manufacturer’s information. If the engine is
installed for return to service, proceed to, "Test
Flight."
20-20 TEST FLIGHT
Refer to the aircraft manufacturer’s or Supplemental
Type Certificate (STC) holders POH/AFM for
specific operational information.
Ambient air and engine operating temperatures are of
major concern during this test flight. Do a normal
preflight run-up in accordance with the Airplane
Flight Manual. Conduct a normal take off with full
power and monitor the fuel flow, RPM, oil pressure,
cylinder head temperatures and oil temperatures.
Reduce to climb power in accordance with the
Airplane Flight Manual. The manual mixture control
should be set in the full rich position for all operations
except leaning for field elevation, leaning to maintain
smoothness during climb and leaning for cruise
economy. Leaning operations must be performed in
accordance with the Airplane Flight Manual.
NOTE…
New, rebuilt and overhauled engines or engines that
have had new or repaired cylinders installed must be
flown in accordance with the following procedure for
the first two hours of operation.
Level flight cruise should be at 75% power with best
power or richer mixture for the first hour of operation.
The second hour power settings should alternate
between 65% and 75% power with the appropriate
best power mixture settings.The best power mixture
setting is 100° to 125° rich of peak turbine inlet
temperature. Engine controls or aircraft attitude
should be adjusted as required to maintain
20-18
engine
temperatures
specifications.
and
pressures
within
Descent from high altitude should be accomplished at
low cruise power settings. During descent engine
pressures and temperatures must be carefully
monitored. Avoid long descents with cruise RPM and
manifold pressure below 18" Hg.
CAUTION…
Rapid descents at high RPM and
pressure are to be avoided.
low manifold
During descent monitor cylinder head and oil
temperatures maintaining above the minimum
recommended operating range.
NOTE…
Avoid long descents at low manifold pressure, which
can result in excessive engine cooling. Satisfactory
engine acceleration may not occur when power is
applied.
Any discrepancies detected during test flight must be
corrected and the aircraft again test flown prior to
approval of engine for return to service. The
appropriate logbook entries must be made in
accordance with Part 43 of the Federal Aviation
Regulations (FAR) before the engine can be returned
to service.
20-21 CONTINUED
AIRWORTHINESS
INSTRUCTIONS
After engine installation, test and approval for return
to service the engine must be kept in an airworthy
status. The engine must be kept airworthy in
accordance with the engine maintenance instructions
in the L/TSIO-360-RB Maintenance Manual, Form
X30645A, and related publications as listed in
Section 1-5 of this manual.